The Sub-Production orders having been put into the departments, the first one will order the material for starting the work. For instance, the first step may be upon iron castings. Theoretically all stock and material come from the Store-Room. Therefore we might say that upon a strict construction of this general rule the castings should be furnished by the Foundry and sent to the Store-Room, from which they might be drawn upon requisitions the same as any other material. Practically this would be not only a troublesome but an expensive method, requiring a great deal of unnecessary handling and transportation. The problem is much more practically solved by considering the Foundry as one of the manufacturing departments receiving its raw material (namely, pig iron) through store-room accounts, and thus "constructively" from the store-room, while physically it is in the foundry yard. This answers the demands of a theoretical as well as a practical view of the case.
Therefore the first sub-production order will go to the iron foundry, which will make the castings and deliver them to such departments as are required to do the first work upon them, as directed upon the order. The sub-production order which this department has received, directs to what department they shall be sent when completed; and so on, until they have gone through the last department and are sent to the Finished Parts Store-Room.
This arrangement is all right as far as it goes. If every man attended strictly to his business and pushed work along as rapidly as possible, and every foreman sent his work along to the next department as soon as his department had completed its work, this plan might work fairly well. Unfortunately, however, these conditions seldom or never exist; and there must be ways and means devised to keep the work moving and to be able to trace and locate the work upon any order at any time when information is desired upon it or its state of progress.
To accomplish this, there is a Transfer Office, located as conveniently as may be for all departments, and serving as a sort of "clearing house" for all departments in transacting inter-departmental business so far as it relates to the transfer of the work in progress. By this method, departments send all their work by way of the Transfer Office, where proper records are kept of all such transfers, so that at any moment the Transfer Clerk can locate any piece of work in progress in the plant.
The operation of this method is as follows: The sub-production orders are sent to the Transfer Clerk, who fills out two Transfer Cards, as shown in Fig. 26, one of which he sends with the order to the first department that is to do work on the order, and the other he retains. This card provides spaces for the various departments, which are designated by numbers. Following these are spaces for entering the dates of transfers, the entries being made with a rubber stamp. After these spaces are columns for the number of pieces of work received and the number of pieces delivered.
When the first department has finished its work, the number of pieces is entered in the column headed Pieces Delivered, and the work and the card sent to the Transfer Office. The duplicate transfer card that was retained by the Transfer Clerk was filed in a compartment in a Transfer Case corresponding to the department where the work began. He stamps the date of transfer on both cards, entering the number of pieces on his own, and sends the work on its way to the next department, together with the transfer card. His own card he removes from the compartment representing the first department, and places it in a compartment representing the department to which he has now sent the work.
Fig. 26. Transfer Card.
Subsequent transfers are made in the same manner, small lots of work actually being sent to the Transfer Office, but large lots or heavy and bulky work being sent directly from one department to the next, but under the personal direction of the Transfer Clerk or his assistant.
When the parts are completed and ready for inspection, the Inspector is notified; and upon inspecting the parts previous to their being sent to the Finished Parts Store-Room, he enters the results of his work in the space at the bottom of the card that has accompanied the work in its progress through the departments.
The Transfer Clerk's card tray is shown in Fig. 27, and is made with compartments of sufficient dimensions to hold the number of cards expected to be on file in anyone department at the same time. The cards are filed in numerical order. In a large concern the usual card-index method of guide cards is used, so as to render the work of finding the right card when wanted, easy and expeditious.