Table Of ContentSCREW AMD EDT MANCFAOTTOB
IN A
SMALXi PLANT
THESIS
Submitted In Partial PulPlllment
of the requirements for the
degree of
MASTER OF MECHANICAL ENGINEERING
at the
POLTTECHNIO INSTITUTE OF BROOKLIN
by
Victor B, Wojtaszek
May 1951
Atorovedi ^
/Tk ae sall sa jAkdAvvil saearr •
I«aa oT MKrtW
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vita
I was born on April 20, 1922, the sixth of seven
ohildren* My parents Initiated my educational training
by enrolling me at a parochial school* At the completion
of this elementary schooling, I enrolled in a scientific
course at Styvesant High School in lower Manhattan, from
which I graduated in 1940, The excellent courses at the
latter school increased an already keen interest in
practical science and mechanics. As a result, the same
year I matriculated at the City College, College of the
City of Hew York in the day session course in mechanical
engineering. The degree of Bachelor of Mechanical
Engineering was awarded me in June, 1944, I immediately
accepted employment in Industry,
My seven years of industrial experience have all been
spent with one manufacturer of communication equipment.
Some of this time has been spent at an associated design
and development laboratory of the same parent corporation.
My engineering duties have been diversified including,
product engineering, preparation of manufacturing and
installation specifications, mechanical design and communica
tion systems development.
At the end of my first year of employment, I decided
to undertake further studies aimed at fulfilling the
requirements for a master*s degree in mechanical engineering.
In the Fall of 1945, I registered at the Polytechnic
Institut© of Brooklyn in a part-time degree program* %ider
the pressure of increased working hours, excessive travelling
time to my employment location and plans for marriage, I
withdrew from my graduate courses at the beginning of the
Spring semester of 1948, and obtained a year's leave of
absence. My studies were resumed in the Fall of 1949.
Work on this thesis has covered a period of approximately
one year* Mo laboratory research has been done, but Instead,
the information has been obtained through library research,
correspondence with manufacturers and public and industrial
informational contacts, and through the application of
knowledge obtained in the formal courses of study* Of special
aid in the organisation of this thesis has been a series of
courses in industrial management, planning and organization
recently added to the graduate mechanical engineering curricu
lum at Polytechnic Institute*
Aoknowld âgement
To the numerous industrial coneems and informational
Institutes referred to throughout this thesis, I owe a debt
of gratitude for their time and efforts in answering Inquiries
addressed to them. Of exoeptlonal assistance were;-
Brown and ^arpe of lew York, Inc,, Providence, E. I#
The National Machinery Go,, Tiffin, Ohio
The Waterbury Parrel Foundry and Machine Co*,
Waterbury, Conn.
I wish to thank Professor Ernst L. Midgette, head of the
Mechanical Engineering Department of the Polytechnic Institute
of Brooklyn for his skillful guidance and wise counsel In the
selection of courses to meet the graduate degree requirements*
To Professor Edward H* Hampel, I extend my heartfelt
appreciation and gratitude for his efforts and patience as
thesis adviser* His capable presentation of a series of four
Industrial management courses helped inmeasurably in the
preparation of this thesis*
Abstract
The purpose of this thesis la to plan a small concern
to manufacture machine screws and nuts of steel and brass
for sale primarily In package lots#
These products were chosen for manufacture because they
represent widely used standardized items requiring no research
or product design effort - costly expenditures for a small
plant# The machine type of screw and nut is a higher quality
type of hardware fastener widely used in light assembly
operations in a great variety of small industrial concerns.
The significance of this is discussed in the next paragraph.
The choice of steel and brass as the materials from which the
products will be fabricated is based on their being the most
commonly used materials. Screws and nuts made from copper,
stainless steel, brass and various non-ferrous metals are
specialty items.
Since the plant will be a relatively small one, the
individual items could not be sold In large, bulk quantities
and thus the sales must be made in package lots, usually of
one gross per package. In general, the small Industrial
concerns mentioned in the preceding paragraph, conSU$m small
quantities of any one Item. They would therefore buy small
package lots of individual items from a distributor rather
than large bulk lots, such as barrels, from a large manufac
turer. Buch packaged sales command a higher price than the
bulk sales. Thus a small concern, located In an area with
small industry like the metropolitan area, would he in a
favorable position to compete with large manufacturers,
especially distant ones, for the local market#
The following facts will control all analysis and
discussions;-
Size of plant - The controlling factor in the selection of
the plant size shall be the equipment investment# This shall
be kept in the f50,000 to #75,000 range# It is desirable to
limit the total number of employees to 10 in harmony with the
plant size.
Plant location - The plant will be located in leased quarters
in a conveniently located rental district in Brooklyn, H.Y.C,
Sales activity area - The sales area will include Mew York
City, Long Island, southern Mew York, lorthem Mew Jersey,
Oonnecticut, and possibly part of Massachusetts, The approxi
mate maximum radius of sales operations will be 200 miles,
although the major portion of the market Is expected to be
within 50 miles of the plant location.
Since the primary motivating force behind any industrial
business venture is the financial profit to be realised, the
selection and analysis of the most profitable process will be
the most important topic. This will occupy so much of the
thesis contents, that no attempt will be made to completely
plan the concern in detail# However, other subjects will also
be considered as required to insure a sound technical and
economical analysis#
fable of Contents
Chapter Content Pages
I History and Development of Fasteners 1-5
II Economic Survey of the Fastener
Industry 6-14
III Product Selection and Specification 15-32
IV Comparison of Two Processes 33-38
Process One
V Analysis and Selection of Machinery -
the Automatic Screw Machine
Process 39-49
VI Material Planning - the Automatic Screw
Machine Process 50-53
VII Production Hates - the Automatic Screw
Machine Process 54-58
VIII Production Costs - the Automatic Screw
Machine Process 59-75
IX Conclusions - the Automatic Screw
Machine Process 76, 77
Process fwo
X Analysis and Selection of Machinery -
for Cold Heading the Same Products 78-98
XI Material Planning - the Cold Heading
Process 99-102
XII Production Rates - the Cold Heading
Process 103-107
XIII Production Costs - the Cold Heading
Process 108-121
XIV Conclusions - the Cold Heading Process 122, 123
XV Miscellaneous Discussions 124-130
XVI Summary 131-136
Index to Tabular Data
Table Title Page
1 General Statistics for the D.8.; 1947
and Earlier Census Tears 7
2 Quantity and Value of Products, Totals
for the G.S.f 1947 and 1939 8
3 List of Products 18
4 Reproduction of ASA B18.6-1947 Table 1 19
6 Reproduction of ASA B18.6-1947 Table 2 20
6 Reproduction of ASA B18.6-1947 Table 3 21
7 Reproduction of ASA B18#6-1947 Table 4 22
8 Reproduction of ASA B18.2-1941 Table 10 23
9 Reproduction of ASA Bl.1-1949 Table 16 27
10 Reproduction of ASA Bl. 1-1949 Table 18 28
11 Sequence of Operations - Screws 46
12 Sequence of Operations - Nuts 47
13 Screw Material Required 62
14 Nut Material Required 63
16 Theoretical Production Rates for Screws 56, 57
16 Theoretical Production Rates for Nuts 68
17 Prices of Steel Bars 62
18 Prices of Free-cutting Yellow Brass Rods 63
19 Equipment Depreciation Costs 66, 66
20 Tooling Costs 67
21 Operating Costs 68
22 Labor Costs 68
Index to Tabular Data (oont'd.)
Table Title Page
23 Total Cost per Year (exel. raw material) 69
24 Production Coat per Gross of Screws 73, 74
26 Production Cost per Gross of Nuts 76
26 Sequence of Operations - Screws 86
27 Sequence of Operations - Nuts 96
28 Screw Material Required 102
29 Nut Material Required 102
30 Theoretical Production Rates for Screws 106, 106
31 Theoretical Production Rates for Nuts 107
32 Prices of Screw Materials 109
33 Prices of Hut Materials 110
34 Equipment Depreciation Costs 112, 113
36 Tooling Costs 114
36 Operating Costs 116
37 Labor Costs 116
38 Total Cost per Year (exel. raw material) 116
39 Production Cost per Gross of Screws 119, 120
40 Production Cost per Gross of Nuts 121
41 Summary of Yearly Production, Costs, Prices
and Profits - Screws 134
42 Summary of Yearly Production, Costs, Prices
and Profits - Nuts 135
43 Annual Operating Profit 136
