Crossley Motors: 1908
Note: This is a sub-section of Crossley Motors.
A MANCHESTER MOTOR CAR WORKS. [1]
A large new factory has been erected by Crossley Brothers, Limited, at Gorton for the express purpose of building motor vehicles on a more extensive scale than formerly. As might have been expected, the new works is equipped in a manner qualified to produce the highest results. The building is of substantial construction, and is chiefly composed of two large shops arranged like the letter L. The machine shop measures 144ft. by 120ft., and the fitting shop 136ft. by 120ft. Power is supplied by a Crossley four-cylinder vertical engine of 180 brake horse-power, using producer gas. The engine has a self-starting apparatus consisting of a separate gas engine and air compressor. It runs at 250 revolutions per minute, and by means of eight ropes drives a line shaft at 200 revolutions per minute. An extension of this line shaft is driven by means of a Benn friction clutch, and this extension drives two other parallel line shafts at the same speed by means of rope pulleys.
The roof of the building is of the saw-tooth pattern, with the teeth carried transversely across the building, excellent illumination in the day time being obtained by north lights. The main girders supporting the roof carry light bowstring longitudinal lattice girders, these girders being provided to carry the overhead countershafts for the machine tools.
The works have been planned by Mr. W. Turner in a compact manner, with all offices and departments on the ground floor. Adjoining the managerial offices is the drawing-office, and next to this is the raw materiel stores. The stores are provided with the usual racks and lockers for the rough parts. Each compartment has a card attached on which the number of articles is given, and the card is subdivided into blank spaces in which may be recorded the number of parts taken out, the dates on which they are taken, and the order number, and the stock remaining. This arrangement forms a check on the bookkeeper. Altogether the system of recording the work through the shop in both books and cards is very thorough.
A convenient but unusual method of storing steel bars and rods is adopted. These are stored in labelled iron racks distributed about the machine shop, and the men are thus able to take what they require without making application to stores. The system has the advantage of relieving the stores space, but an obvious disadvantage presents itself in the case of "wasters."
The machine tools are laid out so as to allow ample space in all directions, and light but solid work tables are conveniently dispersed about the shop. In order to secure accuracy and interchangeability of parts all these are machined to jigs and the limit system of gauging applies throughout. The various operations are denoted by a chart of letters, "A" denoting "turning," "B" "boring" for instance, and a separate drawing is made for each machine operation. This drawing gives all information necessary for that operation, and thus verbal instructions by the foremen are rendered unnecessary. The work is sent into the control room after each operation with the drawing to which it has been made and the progress card. Here each part is examined, and if correct is sent out for the next operation. After this it is again brought in to pass through another inspection. In case of parts being in any way defective they are rejected and a fresh order on the raw material stores made out. It should be stated that orders are placed for a number of ten sets at a time, and no defective parts can be finally rejected without the manager's sanction.
The control room also serves as a store for the gauges. The external limit gauges are given out on receipt of workmen's tickets. When returned and before being replaced in their stand each gauge is tested for accuracy by means of reference bars. All internal work is made to one gauge, any variation being allowed for in the shafts. The finished stores is adjacent to the tool or control room.
It will be gathered from the foregoing somewhat brief review of the workshop system that the organisation and interworking of the various departments is thorough. The machine tools are of the most approved types. We noticed a very effective range of gear-cutting and hobbing machines; a machine by Webster and Bennett for cutting the cams solid on cam shafts; a machine with magnetic table for grinding with great accuracy the edges of piston rings. This machine is made by the Heald Machine Company, Worcester, Mass.
One of the most useful tools in the shop, however, has been built to the manager's, Mr Turner's, own design. It is a horizontal boring machine with two boring heads and has a revolving table to enable the four cylinders of each engine to be bored at one setting. The boring tools are driven by worm gearing, and the cylinders are arranged in brackets on a horizontal revolving table, being brought up to the tools in pairs. The cylinders are finished in two operations — roughing and finishing. After one pair has been roughed out it is turned round on the table and the next pair is similarly treated. This allows the cylinders to cool down before the finishing cut is taken and ensures uniformity throughout each set.
The smiths' shop is a model of cleanliness and good order. It contains gas-heated annealing and hardening furnaces, metal saw and disc grinder, and a fixed gear-box with belt drive for grinding in all gear wheels before they are allowed to be placed in the cars. A commendable feature, which is noticeable throughout the works, is the supply of framed wall cards. One in the smithy intimates to the workers, by means of a table, the sizes and sections of tool steel available. Again, in the tool room, there are framed illustrated instructions for the manufacture of tools and mandrils. All workshop drawings are made to definite standards of size, namely, double-elephant on rolls, half double-elephant on rolls; foolscap and half-foolscap on millboards. These are all stored in racks.
The fitting shop is arranged in separate sections for the different component parts, such as axles, gear boxes, motors, &c. Each bench is provided with a cast iron erecting stand suitable for the work to be erected. These stands are firmly attached to the floor, and give a uniform appearance to the shop by doing away with the usual wooden trestles and packing pieces.
Each bay has an overhead runway and work-tables. The bay for erecting the chassis is large enough to accommodate twenty at one time. It is also provided with erecting stands and overhead runways communicating with the testing department. The latter is a separate fireproof building, measuring 50ft. by 25ft., lofty, well ventilated and lighted. There are six testing stands, fitted up complete with pressure feed petrol tanks, and a cooling water supply service from tanks outside the building. A separate water-pipe line is laid on for cooling the brakes used for testing. The petrol tanks have their own pumps and pressure gauges, and are also connected up to the exhaust pipes of the engines, so as to give as closely as possible the actual conditions of working met with when the engines are fitted on the cars. The tanks are provided with an arrangement whereby any water of condensation formed by the combustion of the gases in the cylinder is separated from the petrol.
Other departments of the works include tinsmiths', woodworking and painting shops. Separate commodious mess-rooms, with cooking apparatus, are provided for the foremen and workpeople. The comfort of the workers has also been considered; lavatories with warm water supplied front the gas engine water jackets and separate lock-up cupboards being provided. The shops are well illuminated at night by Keith's pressure gas system, and they are being equipped with heating apparatus on the plenum system, by which warm air will be forced into and distributed through the buildings by overhead ducts.