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DRAFT
Lighting Equipment, Not Elsewhere Classified
This segment includes establishments primarily engaged in manufactur-
ing lighting fixtures and equipment, electric and nonelectric, not
elsewhere classified. The major products are:
Arc lamps, except electrotherapeutic
Area and sports luminaries
Aviation runway approach, taxi and
ramp lighting fixtures
Decorative area lighting fixtures, except
residential
Flashlights
Floodlights
Fountain lighting fixtures
Gas lighting fixtures
Lamp fixtures, infra-red
Lanterns: electric, gas, carbide, kerosene,
and gasoline
Miners' lamps
Public lighting fixtures
Reflectors, for lighting equipment:
metal
Searchlights
Spotlights, except automobile
Stage lighting equipment
Street lighting fixtures, except traffic
signals
Swimming pool lighting fixtures
Ultra-violet lamp fixtures
Underwater lighting fixtures
Lighting equipment is produced by 184 plants, averaging 68 workers
each. About half of these plants (49 percent) employ more than 20
workers. Additional production data are shown in Table 3-114. As
shown in Figure 3-238, 65 percent of the dollar value of the products
in this category is in the outdoor lighting equipment area and 35
percent is from other electric and nonelectric lighting equipment (in-
cluding hand-portable equipment) and parts and accessories. Steel,
insulated wire and cable, copper, aluminum, castings, resins and
glass are the major raw materials. The principal manufacturing oper-
ations are mechanical material removal, material forming, electro-
chemical processing and assembly operations.
3-616
-------
DRAFT
Lighting equipment is made by a wide range of diverse manufacturing
processes that in general involve machining metal parts, followed
by cleaning, electroplating and final assembly of these parts along
with molded plastic parts and glass. Process water, which constitutes
31 percent of the gross water used by the industry, is used mainly for
rinses after electroplating, acid dips and vapor degreasing.
The manufacture of flashlights (Figure 3-239) is representative of
the lighting equipment industry. First, sheet steel stock and wire-
stock is pretreated in a sulfuric acid bath. The switch contact (and
the metal contact ring located at the base of the reflector) is
stamped. The wire stock is wound to form a steel spring and then heat
treated. These metal parts are then degreased, bright dipped and
electroplated. The barrel, cap, reflector and switch are all plastic
molded with the reflector then coated with graphite or electroless
plate and chrome plated. The clear plastic face plate is cut from
sheets of plastic. Batteries and bulbs are installed and the flash-
light is assembled.
-------
DRAFT
PRODUCTION DATA Lighting equipment, nee
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 90
WITH LESS THAN 20 EMPLOYEES 94
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 12,400
VALUE ADDED BY MANUFACTURE $241.5 MILLION
VALUE OF SHIPMENTS $207.2 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 100
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 10Q
4 PHYSICAL PROPERTY MODIFICATION 0
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS ICO
7 MATERIAL COATING 100
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS Q
WATER USE INCLUDES 3645, 3646, 3647, 3648
ANNUAL GROSS WATER USE 5.9 BILLION GALLONS
22.3 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 51
REUSED WATER AS PERCENT OF GROSS USE 49
PERCENT OF ESTABLISHMENTS REUSING WATER 52
PROCESS WATER AS PERCENT OF GROSS USE 31
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 41
PERCENT OF DISCHARGED WATER TREATED 17
NA NOT AVAILABLE . , . . ^ ,
*Based on Plant Data Collected
TABLE 3-114
3-618
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DRAFT
Radio and Television Receiving Sets,
Except Communication Types
This segment includes establishments primarily engaged in manufactur
ing electronic equipment for home entertainment, including auto
radios and tape players. This industry also includes establishments
primarily engaged in manufacturing public address systems and music
distribution apparatus. The major products are:
Amplifiers: radio, public address, or
musical instrument
Audio electronic systems, except com-
munication
Coin-operated phonographs
FM and AM tuners
Home recorders, cassette, cartridge
and reel
Juke boxes
Loudspeakers, electrodynamic and
magnetic
Microphones
Music distribution apparatus, except
records or tape
Musical instrument amplifiers
Phonograph and radio combinations
Phonograph turntables
Phonographs, including coin-operated
Pickup heads, phonograph
Pillows, stereo
Public address systems
Radio and phonograph combinations
Radio receiving sets
Recording machines, music and speech:
except office and industrial
Sound reproducing equipment: except
motion picture
Speaker monitors
Speaker systems
Television receiving sets
Turntables, for phonographs
Video triggers (remote control TV de-
vices)
3-621
-------
DRAFT
Radio and television receiving sets are produced by 360 plants,
averaging 238 workers each. Almost half of these plants (45 percent)
employ more than 20 workers. Additional production data are shown
in Table 3-115. As shown in Figure 3-240, 45 percent of the products
are household and auto radios, 33 percent are television sets, 12 per-
cent are phonographs, 9 percent are recorders and tuners and 1 per-
cent are electronic kits. Steel, insulated wire and cable, copper,
aluminum, castings, electric motors, electron tubes, semiconductors
and cabinets are the major raw materials. The principal manufacturing
operations are material forming (metals), mechanical material removal,
material coating and assembly operations.
In general, radio and television receiving sets are made by an assembly
operation in which parts, both purchased and manufactured locally, are
assembled, soldered in place, and aligned and tested. Process water,
which constitutes 21 percent of the gross water used by the industry,
is used mainly for cleaning the circuit boards (with detergents and
solvents) after soldering.
The manufacture of television tuners (Figure 3-241) is representative
of the radio and T.V. receiving set industry. Initially, diodes and
capacitors are assembled into shielded cans and the UHF and VHF head-
er plates are prepared. The UHF shielding strip is inserted and tack
soldered. The VHF shielding strip is then inserted and the electronic
components are mounted on printed circuit boards. The boards are
inspected, the leads cut and the boards dip soldered. The boards are
then cleaned in a detergent and/or solvent (chlorinated or fluorinated),
rinsed and dried. All shields are installed along with the strip
wiring. The soldering is inspected and touched up as necessary and
the components are checked. The UHF and VHF tuner is aligned, then
any electronic or mechanical repairs are made. The unit is finally
realigned, and the outer shell installed.
-------
DRAFT
PRODUCTION DATA Radio and Television Receiving Sets, Except
Communication Types
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 159
WITH LESS THAN 20 EMPLOYEES 201
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 85,800
VALUE ADDED BY MANUFACTURE $1,788 MILLION
VALUE OF SHIPMENTS $4,418 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 17
2 MECHANICAL MATERIAL REMOVAL 33
3 MATERIAL FORMING - METALS 33
4 PHYSICAL PROPERTY MODIFICATION 0
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 17
7 MATERIAL COATING 33
8 ORE PROCESSINGS-REFINING 17
9 MOLDING* FORM ING-NON-METALS Q
WATER USE
ANNUAL GROSS WATER USE 5.7
21.6
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
47
53
50
21
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
44
0
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-515
3-623
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3-625
-------
DRAFT
Phonograph Records and Pre-recorded
Magnetic Tape
This segment includes establishments primarily engaged in manufactur-
ing phonograph records and pre-recorded magnetic tape. The major
products are:
Magnetic tape, pre-recorded
Master records or tapes, preparation of
Phonograph record blanks
Phonograph records (including prepa-
ration of the master)
Pre-recorded magnetic tape
Record blanks, phonograph
Recording studios
Records, phonograph
Tape, magnetic: pre-recorded
Phonograph records and pre-recorded magnetic tapes are produced by
564 plants, averaging 36 workers each. Most of these plants (79
percent) employ less than 20 workers. Additional production data
are shown in Table 3-116. As shown in Figure 3-242, about 58 per-
cent of the products produced in this category are 45 rpm records
and 41 percent are 33 1/3 rpm records. Cartridge tapes and cassette
tapes account for less than 1 percent of the total production.
Plastic and magnetic tapes are the major raw materials, while the
principal manufacturing operations are molding and forming (non-metals)
and chemical/electrochemical operations.
In general, phonograph records are made by molding plastic from a
negative master disc. Pre-recorded magnetic tapes are made by pass-
ing mylar tape coated with iron oxide in front of a recording head.
Process water, which constitutes 11 percent of the gross water used
by the industry, is used mainly for removing dust and dirt from the
master disc.
The manufacturing operations for fabricating phonograph records and
pre-recorded magnetic tapes are shown in Figure 3-243. The first
step in the manufacture of phonograph records is to machine a metal
disc which serves as the master disc. Next, this disc is coated
with plastic which is then grooved by the recording cutter. The
disc is then coated with lacquer and a negative is made by electro-
forming. If this negative master is to be used to make a large
-------
DRAFT
quantity of records, it is made from high grade steel. The negative
master is then used as a mold in a plastic molding operation which
is usually done under pressure with heat.
The plastic, if it is for low cost records, is a synthetic thermo-
plastic containing fillers. High quality records are made with
vinyl plastic without filler because the fillers cause a scratch-
ing sound when played.
Pre-recorded magnetic tapes are made from thin sheets of mylar that
are coated with iron oxide and slit into strips of 6.35 mm or 3.175 mr
wide. The magnetic tape is then wound on plastic spools. It is
recorded by passing the tape at a constant speed through a recording
machine. Many manufacturers of pre-recorded tape simply purchase
the magnetic tape and do only the recording themselves.
3-627
-------
DRAFT
PRODUCTION DATA Phonograph Records and Pre-recorded Magnetic Tape
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 120
WITH LESS THAN 20 EMPLOYEES 444
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 20 , 300
VALUE ADDED BY MANUFACTURE $372.5 MILLION
VALUE OF SHIPMENTS $563.9 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTINGS MOLDING-METALS 0
2 MECHANICAL MATERIAL REMOVAL 50
3 MATERIAL FORMING - METALS 50
4 PHYSICAL PROPERTY MODIFICATION 50
5 ASSEMBLY OPERATIONS 50
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS ]_00
7 MATERIAL COATING
8 ORE PROCESSING & REFINING
9 MOLDING & FORMiNG - NON-METALS
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WATER USE
ANNUAL GROSS WATER USE 4.6 BILLION
17.4 BILLION
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
GALLONS
LITERS
33
67
50
11
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
28
0
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-116
3-628
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-------
DRAFT
Telephone and Telegraph Apparatus
This segment includes establishments primarily engaged in manufactur-
ing wire telephone and telegraph equipment, and parts especially de-
signed for telephone and telegraph use. The principal products are:
Autotransformers for telephone switchboards
Carrier equipment, telephone and telegraph
Communication headgear, telephone
Data sets, telephone and telegraph
Electronic secretary
Headsets, telephone
Message concentrators
PBX equipment, dial and manual
Switchboards, underwater: telephone and telegraph
Telegraph office switching equipment
Telephone central office equipment, dial and manual
Telephone dialing devices, automatic
Telephone sets, all types
Telephone station equipment and parts, wire
Telephones, sound powered (no battery)
Telephones, underwater
Teletypewriters
Telewriters
Telephone and Telegraph Apparatus are produced by 200 plants, averagir
675 workers each. Most of these plants (56 percent) employ more than
20 workers. Additional production data are shown in Table 3-117.
Forty percent of the dollar value produced in this category is from
Telephone Switching and Switchboard Equipment, 12 percent is from
Telephone carrier equipment, 40 percent is from Telephone instruments
sets, 7 percent is from Telegraph apparatus and 1 percent is from
other equipment. As shown in Figure 3-244, steel, wire, copper,
aluminum, castings, resins, electron tubes and semiconductors are the
major raw materials. The principal manufacturing operations are
mechanical material removal, material forming, material coating,
chemical/electrochemical operations, physical property modification,
and molding and forming (non-metals).
Telephone and Telegraph Equipment is made by a wide range of diverse
manufacturing processes. Typically, the chassis and cabinet are
manufactured and the components are installed and wired. Telephone
shells are molded plastic. Actual process water is used mainly for
electroplating, etching, painting, anodizing, cleaning and air
scrubbing.
-------
DRAFT
The manufacture of PBX Equipment (Figure 3-245) is representative
of the Telephone and Telegraph industry. First the cabinet and
chassis are formed by stamping, shearing, bending, spot welding,
grinding, pickling, and painting. The chassis is then drilled and
the components such as purchased pre-wired circuit boards, relays
and transformers are installed. These parts are assembled either
by soldering or wire wrapping. Wire wrapping is now being used
throughout the industry because of its superior mechanical and
electrical properties. It is also a dry process as opposed to dip
soldering.
3-632
-------
DRAFT
PRODUCTION DATA Telephone and Telegraph Apparatus
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 111
WITH LESS THAN 20 EMPLOYEES &9
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 134,900
VALUE ADDED BY MANUFACTURE $2,645.2 MILLION
VALUE OF SHIPMENTS $4,531.1 MILLION
+
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING-METALS 28
2 MECHANICAL MATERIAL REMOVAL 86
3 MATERIAL FORMING - METALS 72
4 PHYSICAL PROPERTY MODIFICATION 72
5 ASSEMBLY OPERATIONS 86
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 72
7 MATERIAL COATING 43
8 ORE PROCESSINGS REFINING 0
9 MOLDING & FORMING - NON-METALS 86
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
NA NOT AVAILABLE
*BASED ON PLANT DATA COLLECTED
TABLE 3-117
3-633
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Radio and Television Transmitting, Signaling, and
Detection Equipment and Apparatus
This segment includes establishments primarily engaged in manufactur-
ing (1) radio and television broadcasting equipment; (2) electric
communication equipment and parts, except telephone and telegraph;
(3) electronic field detection apparatus, light and heat emission oper-
ating apparatus, object detection apparatus and navigational elec-
tronic equipment, and aircraft and missile control systems; and (4)
high energy particle accelerator systems and equipment designed and
sold as a complete package for radiation therapy, irradiation, radio-
graphic inspection, and research (linear accelerators, betatrons,
dynamotrons, Vandergraff generators, resonant transformers, insulating
core transformers, etc.); (5) high energy particle electronic equip-
ment and accessories sold separately for the construction of linear
accelerators, cyclotrons, synchrotrons, and other high energy research
installations (transmitters/modulators, accelerating wave-guide struc-
tures, pulsed electron guns, vacuum systems, cooling systems, etc.);
(6) other electric and electronic communication and signaling products,
not elsewhere classified. Particular products are:
Accelerating waveguide structures
Air traffic control systems and equip-
ment, electronic
Aircraft control systems, electronic
Amplifiers: other than radio, public address,
and musical instrument
Antennas, radar and communications
Antennas, television transmitting
Atom smasher (particle accelerators)
Betatrons
Broadcasting equipment, radio and tele-
vision
Burglar alarm apparatus, electric
Cleaning equipment, ultrasonic
Communication equipment and parts,
electronic: except telephone, tele-
graph
Communication equipment, mobile and micro-
wave
Control-receivers
Countermeasure simulators, electric
Cyclotrons
Detection apparatus: electronic and mag-
netic field, and light and heat
Digital encoders
-------
DRAFT
Direction finders, radio
Door opening control devices, radio and
photoelectric cell operated
Dynamotrons
Electron beam metal cutting, forming
and welding machines
Electron beam welders
Electron linear accelerators
Electronic control, detection, or com-
munication systems
Electronic field detection apparatus
Electrostatic particle accelerators
Facsimile equipment, radio
Fire alarm apparatus, electric
Fire control and bombing equipment,
electronic
Flight simulators (training aids)r elec-
tronic
Geophysical and meteorological elec-
tronic equipment
Heat emission operating apparatus
Highway signals, electric
Hydrophones
Inertial guidance systems
Infra-red object detection equipment
Instrument landing systems (ILS), air-
borne and ground
Intercommunication systems, electric
Laser systems and equipment, except
scientific and engineering instru-
ments
Light and heat emission operating apparatus
Linear accelerators
Loran equipment
Magnetic amplifiers, except home type
Magnetic field detection apparatus
Marine horns, electric
Maser equipment, all types
Micro-wave communication equipment
Missile control systems
Missile fuel management systems
Mobile communication equipment
Modems, except telephone and tele-
graph data sets
Multiplex equipment
Navigational electronic equipment (ILS,
DME, VOR, TACAN)
Object detection apparatus (radar/
Particle accelerators, high voltage
-------
Photographic control systems, electronic
Phototransmission equipment, radio
Pulsed electron guns
Radar equipment
Radio and television switching equip-
ment
Radio antennas (transmitting and receiving)
and ground equipment
Radio compasses
Radio receiver networks
Radio telephone and telegraph equip-
ment, except tubes
Railroad signaling devices, electric
Receiver-transmitter units (transceiv-
er)
RF power amplifiers, and IF ampli-
fiers: sold separately
Satellites
Sighting and fire control equipment,
electronic type
Signaling apparatus, electric
Signals: railway, highway, and traffic -
electric
Sirens, electric: vehicle, marine, indus-
trial, and air raid
Sonar equipment
Sound signaling devices, electrical
Target signals, synthetic: to operate radar
receivers and repeaters
Telemetering equipment, electronic
Television antennas (transmitting) and
ground equipment
Television closed circuit equipment
Television monitors
Time decoders
Traffic signals, electric
Training devices, electronic
Transmitting apparatus, radio and tele-
vision: except tubes
Transponders
Ultrasonic cleaning equipment
Ultrasonic generators sold separately
for inclusion in tools and equipment
Ultrasonic welding machines and equipment
Underwater sound equipment
Waveguide pressurization equipment
Weapon simulators
-------
DRAFT
Radio and television transmitting, signaling, and detection equipment
and apparatus are produced by 1698 plants, averaging 188 workers each.
About half of these plants (51 percent) employ more than 20 workers.
Additional production data are shown in Table 3-118. As shown in
Figure 3-246, 74 percent of the products produced in this category
are video equipment, 14 percent are transceivers, 4 percent are amatet
radios, 4 percent are cab radios and 4 percent are audio equipment.
Steel, copper, aluminum, insulated wire and cable castings, electric
motors, electron tubes, semiconductors, and plastic resins are the
major raw materials. The principal manufacturing operations are
mechanical material removal, material coating, material forming (metal
and chemical/electrochemical operations.
In general, equipment in this category is made by bending and forming
sheet metal stock into the cabinet and the chassis, building the print
ed circuit boards, and final assembly of all the components. Process
water is used mainly for cleaning and pickling of the metal stock and
air scrubbing in the painting booths.
The manufacture of electronic communication equipment (Figure 3-247)
is representative of this industry. The cabinet and the chassis for
the equipment is formed first by shearing sheet metal stock, trimming
the metal, drilling the holes for the components and deburring. Next
the metal is bent and formed and spot welded together to form the
cabinet which is then pickled, galvanized with zinc, and painted.
The circuit boards for the units are etched and the components (re-
sistors, capacitors, transistors, etc.) are mounted into place. The
leads are trimmed and the board is dip soldered. These circuit boards
along with purchased components are then assembled into the chassis.
The components are wired by soldering or wire wrapping. The unit is
then inspected, tuned and tested.
-------
DRAFT
PRODUCTION DATA Radio and TV commur.irM.ion
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 867
WITH LESS THAN 20 EMPLOYEES 83i
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 319,600
VALUE ADDED BY MANUFACTURE $5750.3 MILLION
VALUE OF SHIPMENTS $9] 28.2 MILLION
1
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
! CASTING & MOLDING - METALS 10
2 MECHANICAL MATERIAL REMOVAL 90
3 MATERIAL FORMING - METALS 50
4 PHYSICAL PROPERTY MODIFICATION 20
5 ASSEMBLY OPERATIONS 90
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 40
7 MATERIAL COATING 40
8 ORE PROCESSING & REFINING 0
9 MOLDINGS FORMING-NON-METALS 30
WATER USE
ANNUAL GROSS WATER USE
NA
NA
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCES1 ' TER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
NA
NA
NA
NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-1 Ifi
-------
DRAFT
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DRAFT
Radio and Television Receiving Type Electron
Tubes, Except Cathode Ray
This segment includes establishments primarily engaged in manufactur-
ing radio and television receiving type electron tubes, except cathode
ray tubes.
Radio and T.V. receiving type electron tubes are produced by 24
plants, averaging 515 workers each. Half of these plants (50 per-
cent) employ more than 20 workers. Additional production data are
shown in Table 3-119. As shown in Figure 3-248 70 percent of the
radio and T. V. receiving tubes manufactured are miniature, 14 per-
cent are standard tubes and 16 percent are subminiature and other types
of tubes. Steel, copper, semiconductors, glass and resins are the
major raw materials. The principal manufacturing operations are
mechanical material removal, physical property modification, material
forming (metals) and chemical/electrochemical operations.
In general, electron tubes are made by machining the metal parts,
working the glass parts, assembling the components, exhausting the
tube, testing, cleaning, and electroplating. Process water, which
constitutes 5 percent of the gross water used by the industry, is
used mainly for cleaning before furnacing, glass working, testing
and electroplating.
The manufacture of electron tubes for radio and television receiving
sets (Figure 3-249) is representative of this industry. Tubes
generally consist of a button stem assembly, shields, spacers, heat-
er cathode, grid, plate and a getter. The button stem assembly is
usually preassembled from glass and electrodes. The cathode, grid,
plate, spacers and heater are combined into a cage assembly which is
then mounted onto the button stem. A glass envelope is then placed
over the cage and heated to seal it to the button stem. The air is
then exhausted and sometimes an inert gas added and the envelope is
sealed. The shields and the spacers are usually stamped from thin
"£Keets of formica or ceramic. The heater is usually a tungsten wire
coated with a layer of aluminum oxide and the cathode is usually a
tungsten filament with a coating of barium oxide, stranium oxide and
calcium oxide. This coating is done by making a slurry of carbonates
in nitro-cellulose that is highly diluted with organic solvents such
as amye acetate. This slurry is then sprayed onto the filament.
The grid is made of two side rods with lateral wires wound around
them. The rods are nicked to locate the lateral wires which are spot
3-643
-------
on/, FT
PRODUCE 'ON DAT Rcdio an' Television Receiving Type Eleccron j^
E, ce»t Ca .node ilav ____—.
NUMBE -; OF tL^TAB ISHML;N S VVI 'H MORE TH ;•> 2J MSLOY ES
WiTH LESS T^AN 20 EMPLOYEES 12
NUMBER OF ^MP OY 25 ALL ,rSs ABLJSHM :NTS 11, ^00
VALUE ADDED BY MANUFACTURE $17J MILLION
VALUE OF SHIPMENTS $226.2 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 C STING & MOLDING - PETALS
2 MEr.HANICAL MATERIAL €MOVAL
3 MATERIAL FORMING - METAL.S
4 PHYSICAL P OPE, TY MODIFICATION
b ASSEMBLY OPERATIONS
33
67
0
0
33
6 CHEMI<~AL-E ECTROCHEMICAL Oi-ERATICNS 1 00
/ MATERIAL COATING
8 ORE PROCESSING & REF.NING
9 MOLDING & FORMING - NON-ME^A S
67
u
0
WATER -I
JWA IR USE 5.9
"2.3
I, TAKE WATER AS PE CEN O ' CROSS USE.
REUSED WATER f- S PERCENT OF CROSb S"
PERCENT OF ESTABLISHMENTS REUSIN i V.AT
PROr_SS WATER AS PERCENT OF ^ROSS USE
EILLI N GAL: ->N
BILLION LITERS
17
83
69
5
DlSCHArioED WAT^R AS PERCENT r. GROSS JPE 25
PERC£NT OF DISCHARGED WATER TREATED 0
NOTAVAIL/BLE
*Based on Plant Data Collected
TABLE 3-119
3-645
-------
DRAFT
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3-647
-------
DRAFT
Cathode Ray Television Picture Tubes
This segment includes establishments primarily engaged in manufactur-
ing television receiving type cathode ray tubes. The major products
are:
Cathode ray television receiving type
tubes
Picture tube reprocessing
Cathode ray television picture tubes are produced by 74 plants,
averaging 212 workers each. Most of these plants (72 percent)
employ less than 20 workers. Additional production data are shown
in Table 3-120, and Figure 3-250. Thirty percent of the television
picture tubes produced are black and white and 70 percent are color.
Copper, kovar, nickel, aluminum, lead, glass, ceramic compounds
(aluminum oxides), silver solders and brazing alloys are the majcr
raw materials. The principal manufacturing operations are mechanical
material removal, material forming (metals) and chemical/electro-
chemical operations.
In general cathode ray T.V. picture tubes are made by machining the
metal parts, working the glass parts, assembling the components,
vaporizing the phosphors on the inside of the tube, exhausting the
tube, testing, cleaning and electroplating. Process water, which
constitutes 29 percent of the gross water used by the industry, is
used mainly for cleaning before furnacing, glass working, testing
and electroplating.
The manufacture of cathode ray picture tubes (Figure 3-251) is
representative of the processes used in this industry. Cathode ray
tubes are made essentially the same as conventional electron tubes
with the major difference oeing the fact that cathode ray tubes
contain a phosphorescent screen and a cathode ray gun. The phosphor-
escent screen is made of a thin coating of inorganic material that
becomes luminescent under electron bombardment. The phosphers are
vapor deposited on the inside of the tube. The electron gun is made
very similar to the metal parts of a conventional tube, the major
difference being the shape of the internal parts. For further de-
tails on the manufacture of conventional electron tubes see the
description in SIC 3671.
3-648
-------
DRAFT
PRODUCTION DATA Cathode Ray Television Picture Tubes
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 21
WITH LESS THAN 20 EMPLOYEES 53
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 15,700
VALUE ADDED BY MANUFACTURE $345.5 MILLION
VALUE OF SHIPMENTS $696.4 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS NA
2 MECHANICAL MATERIAL REMOVAL NA
3 MATERIAL FORMING - METALS NA
4 PHYSICAL PROPERTY MODIFICATION NA
5 ASSEMBLY OPERATIONS NA
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS NA
7 MATERIAL COATING NA
8 ORE PROCESSING & REFINING NA
9 MOLDING & FORMING-NON-METALS NA
WATER USE
ANNUAL GROSS WATER USE 5.5
20.8
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
53
47
100
29
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
51
39
NA NOT AVAILABLE
*BASED ON PLANT DATA COLLECTED
TABLE j 1
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3-651
-------
DRAFT
Transmitting, Industrial, and Special
Purpose Electron Tubes
This segment includes establishments primarily engaged in manufactui
ing transmitting, industrial, and special purpose electron tubes.
The major products are:
Cathode ray tubes, except television re-
ceiving type
Electron beam (beta ray) generator
tubes
Electron tubes: transmitting, indus-
trial, and special purpose
Gas and vapor tubes
Geiger Mueller tubes
Industrial electron tubes
Klystron tubes
Light sensing and emitting tubes
Magnetrons
Transmitting electron tubes
Traveling wave tubes
Tubes for operating above the X-ray
spectrum (with shorter wave length)
Vacuum capacitors, relays, and
switches
Transmitting, industrial and special purpose electron tubes are pro-
duced by 51 plants, averaging 394 workers each. Most of these plant
(71 percent) employ more than 20 workers. Additional production dat
are shown in Table 3-121 and Figure 3-252. Fifty-eight percent of
the electron tubes produced in this category are high vacuum tubes,
33 percent are gas and vapor tubes, 2 percent are magnetrons, and 7
percent are other electron tubes. Copper, kovar, nickel, aluminum,
lead, glass, ceramic compounds (aluminum oxides), silver solders
and brazing alloys are the major raw materials. The principal manu-
facturing operations are mechanical material removal, chemical/
electrochemical operations, material coating, material forming
(metals) and physical property modification.
3-652
-------
DRAFT
l~r - eiec: fe-r©n-~t-tttee s- -a r-e - ma de by. .m*&h in i-n g t he- «e fe a 1
working the glass parts, assembling the components,.- exhausting !
the tube j J^stijigij cleaning^ and ^eleetrqjolating_. Pr£cess_water, *
Which constitutes 10 percent of the gross water used by the industry
is used mainly for cleaning before furnacing, glass working, testing
and electroplating.^ " '- " "'• • ,- '•> -. . - '- -'*
The manufacture of "special purpos'e electron tubes (Figure 3-253)!> is
representative of this industry. The raw materials- are- divided up
into two classes, metal and glass. The metals are machined and fornv
as required, then degreased and cleaned in an ultrasonic cleaner.
Furnacing is done to drive out any gases trapped,within the metal.
The glass parts are cleaned in an alkalai bath and then worked into
the required shapes such as a glass envelope.
Next, the metal parts are brazed together, then inserted in the glas
tube which is next exhausted of all gases. The assembled tube is
then cleaned in a pickling solution and tested. It is cleaned again
and the external parts of the tube are electroplated.
3-653
-------
DRAFT
PRODUCTION DATA n octroi". Tutc-S
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 36
WITH LESS THAN 20 EMPLOYEES 15
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 20. ICO
VALUE ADDED BY MANUFACTURE 5337.1 MILLION
VALUE OF SHIPMENTS 5471.6 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 33
I MECHANICAL. MATERIAL REVOVAL £"
3 MATERIAL FORMING - METALS C
4 PHYSICAL PROPERTY MODIFICATION C
5 ASSEMBLY OPERATIONS 33
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS IOC
7 MATERIAL COATING 67
8 ORE PROCESSINGS-REFINING -
9 MOLDING & FORMING - NON-METALS C
WATER USE
ANNUAL GROSS WATER USE 4.2 BILLION GALLONS
15.9 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 36
REUSED W ATER AS PERCENT OF GROSS USE 64
PERCENT OF ESTABLISHMENTS REUSING WATER 75
PROCESS WATER AS PERCENT OF GROSS USE 10
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 33
PERCENT OF DISCHARGED WATER TREATED 29
NA NOT AVAILABLE *BAsr.u UIN t-i^ ^
TABLE 3-121
3-654
-------
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DRAFT
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DRAFT
Semiconductors and Related Devices
This segment includes establishments primarily engaged in manufactur-
ing semiconductor and related solid state devices, such as semi-
conductor diodes and stacks, including rectifiers, integrated micro-
circuits (semiconductor networks) transistors, solar cells, and light
sensing and emitting semiconductor (solid state) devices. The princi-
pal products are:
Computer logic modules
Controlled rectifiers, solid state
Diodesf solid state (germanium, sili-
con, etc.)
Electronic devicesf solid state
Fuel cells, soiJfS state
Gunn effect device
Kail effect devices
Hybrid integrated circular
Infra-red ;-; en £":.::£ , solid state-
Light e-r.irti":g c'io>?es
Light sensitive device;-: f solid state
Magnetic buL'?]e meraory 03vice
i»iagnetohydrccyj>imic (Mi-iD} o.«v ic;
' ^s C'
.Memories,, s
d state
#etai oxide silicon ^MCE) devices
Microcircuits , ir tegratec (semicon-
ductor ;
Modules ; solid ctate
Molecular devices, solid state
Monolithic integrated circuits (solid
Kuclear detectors f ,:>:, lid state
Paremstric clicaes
Photoelectric cells, solid state (elec
tronic eye/
Fliotovoltaic devices, scl:d £v,e:te
Pectiliersf solid state
Semicor.ouctcr circuit nstv^arks (solid
state integrated circuits)
Semiconductors (transistors, diodes,
etc.)
S"olar cells
Solid state electronic devices
Strain gages, solid state
Stud bases or mounts for semicon-
ductor devices
Switches, silicon control
3-657
-------
DRAFT
Thermionic devices, solid state
Thermoelectric devices, solid state
Thin film circuits
Transistors
Tunnel diodes
Ultra-violet sensors, solid state
Variable capacitance diodes
Zener diodes
Semiconductors and related devices are produced by 313 plants,
averaging 270 workers each. Most of these plants (59 percent)
employ more than 20 workers. Additional production data are
shown in Table 3-122. As shown in Figure 3-254, 36 percent of
the products produced in this category are transistors, 44 per-
cent are diodes and rectifiers, 16 percent are integrated cir-
cuits and 4 percent are other semiconductors. Steel, insulated
wire cable, aluminum, copper, castings, silicon, germanium and
resins are the major raw materals. The principal manufacturing
operations are mechanical material removal, chemical/electro-
chemical operations and material forming (metals).
In general semiconductors are made from silicon or germanium wafers
that are doped with impurities. These are joined together and lead
wires are attached. Process water, which constitutes 6 percent of
the gross water used by the industry, is used mainly for washing
the finished semiconductor device with ultra pure water.
The manufacture of transistors (Figure 3-255) is representative
of the semiconductors industry. (Crystals of silicon are first
grown by the Czochralski or Float Zone methods. They are next cut
and polished to form wafers.) Next, the wafers are cast and sorted,
They are then bonded together and wires are bonded to the joined
wafers. The unit is next washed in ultra pure water, dried and
baked. A cap is finally soldered into place and the unit tested.
3-658
-------
DRAFT
PRODUCTION DATA Semiconductors and Related Devices
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 184
WITH LESS THAN 20 EMPLOYEES 129
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 84,600
VALUE ADDED BY MANUFACTURE $1423.6 MILLION
VALUE OF SHIPMENTS $2176.2 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING-METALS 0
2 MECHANICAL MATERIAL REMOVAL 29
3 MATERIAL FORMING - METALS 0
4 PHYSICAL PROPERTY MODIFICATION 14
5 ASSEMBLY OPERATIONS 86
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 100
7 MATERIAL COATING 57
8 ORE PROCESSINGS REFINING 0
9 MOLDING & FORMING - NON-METALS 29
WATER USE
ANNUAL GROSS WATER USE 44
166.5
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
75
85
86
6
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
14
43
NA NOT AVAILABLE
* Based on Plant Data Collected
TABLE 3-122
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DRAFT
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DRAFT
Electronic Capacitors
This segment includes establishments primarily engaged in manufactur-
ing electronic capacitors. The major products are:
Capacitors, electronic: fixed and vari-
able
Condensers, for electronic end products
Electronic capacitors are produced by 107 plants, averaging 251 work-
ers each. Most of these plants (90 percent) employ more than 20
workers. Additional production data are shown in Table 3-123. As
shown in Figure 3-256, 18 percent of the capacitors produced are
electrolytic capacitors, 76 percent are ceramic capacitors and 6 per-
cent are mica capacitors. Various metal stock, wire and dielectric
materials are the major raw materials. The principal manufacturing
operations are material coating, assembly operations, and physical
property modification.
In general, capacitors are made by forming discs, applying a silver
surface to both sides, oven drying, attaching lead wires and plastic
coating the unit. Process water, which constitutes 12 percent of
the gross water used by the industry, is used mainly for cleaning
after the leads are dip soldered in place.
The manufacture of ceramic disc capacitors {Figure 3-257) is represen-
tative of the capacitor industry. First a ceramic disc is formed and
oven fired. A silver surface is applied to each side of the disc and
it is oven dried. The discs are then loaded into a magazine where
wires which have been previously stripped, cut and bent are attached
by dip soldering. The disc assembly is then cleaned in a detergent
or solvent. A plastic coating is applied and the capacitor is dried.
Identification is printed on the capacitor and a wax coating is
applied. The wire leads are then sheared and samples of the capacitors
are tested.
-------
DRAFT
PRODUCTION DATA Electror.ic capacitors
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 96
WITH LESS THAN 20 EMPLOYEES 11
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 26,900
VALUE ADDED BY MANUFACTURE $296.0 MILLION
VALUE OF SHIPMENTS $437.9 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
i CASTJNG & MOLDING - METALS 50
2 MECHANICAL MATERIAL REMOVAL 50
3 MATERIAL FORMING - METALS 50
4 PHYSICAL PROPERTY MODIFICATION 50
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATfONS 50
7 MATERIAL COAT5NG 50
8 ORE PROCESS5NG & REFINING 50
9 MOLDING & FORMING - NON-METALS 0
WATER USE
ANNUAL, GROSS WATER USE 2&. 3 bil.LIOrt GALLONS
1C7.I BILLION LITERS
INTAKC WATER AS PERCKN1 CF GROSS USE 32
REUSED WATER AS PERCENT OF GROSS USE 68
PERCENT OF ESTABLISHMENTS REUSING WATER 55
PROCESS WATER AS PERCENT OF GROSS USE 12
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 29
PERCENT or DISCHARGED WATER TREATED 33
NA NOT AVAILABLE
*'ili<,r-d on Plant Data Collected
TABLE 3-123
J-663
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DRAFT
Resistors for Electronic Applications
This segment includes establishments primarily engaged in manufactur-
ing resistors for electronic end products. The products are:
Resistors, for electronic end products
Thermistors, except temperature sensors
Varistors
Resistors, for Electronic Applications are produced by 83 plants,
averaging 234 workers each. Most of these plants (90 percent)
employ more than 20 workers. Additional production data are shown
in Table 3-124. As shown in Figure 3-258, 59 percent of all re-
sistors produced are composition resistors, 28 percent are de-
posited carbon or metal film resistors, 5 percent are variable non-
wire wound resistors, 4 percent are wire wound resistors, 2 percent
are variable wire wound resistors and 2 percent are other types of
resistors. The principal manufacturing operations are material
coating, molding and forming (non-metals), assembly operations and
physical property modification.
In general resistors are made by forming the ceramic substrate and
filming, curing and coating it in the case of a deposited film
resistor. Wire wound resistors are produced very similarly to
transformers. Process water which constitutes 12 percent of the
gross water used by the industry, is used mainly for cleaning.
The manufacture of carbon film resistors (Figure 3-259) is representa-
tive of the resistor industry. Initially the ceramic substrate
is formed and oven fired. The carbon film is then deposited on
the substrate in a methane atmosphere at (1038 degrees C). The resis-
tance of the resulting film is measured next. Silver contact bands
are applied as silver powder in a vehicle binder. Drying and curing
is next, followed by a dip in a silicon compound and centrifuging.
The resistor is then cured, sorted, spiralled and capped. An
epoxy coating is applied and the resistor is tested and marked.
-------
DRAFT
PRODUCTION DATA Electronic resistors
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES
WITH LESS THAN 20 EMPLOYEES
75
8
19,400
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS
VALUE ADDED BY MANUFACTURE $251.7 MILLION
VALUE OF SHIPMENTS $350.6 MILLION
4
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS NA
2 MECHANICAL MATERIAL REMOVAL NA
3 MATERIAL FORMING - METALS NA
4 PHYSICAL PROPERTY MODIFICATION NA
5 ASSEMBLY OPERATIONS NA
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS NA
7 MATERIAL COATING NA
8 ORE PROCESSING & REFINING NA
9 MOLDING & FORMING-NON-METALS NA
WATER USE
ANNUAL GROSS WATER USE 28.3
107.1
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
32
68
55
12
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
29
33
NA NOT AVAILABLE
*BASI:D ON PLANT DATA COLLECTED
TABLE 3-124
3-667
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DRAFT
Electronic Coils, Transformers
and Other Inductors
This segment includes establishments primarily engaged in manufactur-
ing electronic coils, transformers and inductors. The major products
are:
Baluns
Coil windings, electronic
Coils, chokes and other electronic in-
ductors
Filters, electronic
Inductors, electronic
Transformers, electronic types
Electronic coils, transformers and other inductors are produced
by 222 plants, averaging 115 workers each. Most of these plants
(83 percent) employ more than 20 workers. Additional production
data are shown in Table 3-125. As shown in Figure 3-260 23 percent
of the dollar value of products in this category is for television
transformers, 24 percent is for RF transformers, 24 percent is for
plate and filament transformers and 29 percent is for other electronic
coils. Insulated wire and cable, steel and paper are the major raw
materials and the principal manufacturing operation is assembly.
In general, electronic coils are made by winding the coil, install-
ing the leads, and assembling the coil to a base. Process water,
which constitutes 12 percent of the gross water used by the industry,
is used mainly for cleaning after soldering.
The manufacture of I.F. transformers (Figure 3-261) is representative
of the transformer industry. First the coils are wound on a form
and the leads are pressed into a phenolic base. The capacitor is
then installed on the base and dip soldered. The joint is then
cleaned with a solvent. Next, the base is connected to the coil
and the coil leads are soldered. The slug and the ferrite cap is
then installed and the unit is inspected. Finally the shielding
can is installed and the transformer is tested and adjusted.
-------
DRAFT
PRODUCTION DATA Electronic coils and transformers
NUMBER OF ESTABLISHMENTS. WITH MORE THAN 20 EMPLOYEES 184
WITH LESS THAN 20 EMPLOYEES 38
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 25, 500
VALUE ADDED BY MANUFACTURE $214.7 MILLION
VALUE OF SHIPMENTS $355.8 MILLION
^
PERCENT OF ESTABLISHMENTS USING VARIOUS .MANUFACTURING OPERATIONS,
1 CASTINGS MOLDING-METALS
2 MECHANICAL MATERIAL REMOVAL
3 MATERIAL FORMING - METALS
4 PHYSICAL PROPERTY MODIFICATION
5 ASSEMBLY OPERATIONS
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS
7 MATERIAL COATING
8 ORE PROCESSING & REFINING
9 MOLDING & FORMING - NON-METALS
0
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100
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WATER USE INCLUDES 3675, 3676, 3677, 3678, 3679
ANNUAL GROSS WATER USE 28.3
NA
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
32
68
55
12
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
29
33
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-125
3-671
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DRAFT
Connectors for Electronic Applications
This segment includes establishments primarily engaged in manufactur-
ing connectors for electronic applications.
Connectors for electronic applications are produced by 90 plants,
averaging 179 workers each. Most of these plants (87 percent) employ
more than 20 workers. Additional production data are shown in Table
3-126. As shown in Figure 3-262, 21 percent of the products produced
in this category are radio frequency connectors, 10 percent are
cylindrical connectors, 68 percent are printed circuit connectors
and 1 percent are fusion sealed connectors. Steel, copper, silver,
gold, wire and cable and plastics are the major raw materials. The
principal manufacturing operations are molding and forming (non-
metals) , mechanical material removal, assembly operations, and
chemical/electrochemical operations.
In general electrical connectors are made by stamping electrical
contacts and electroplating them, molding the plastic shell and
assembling the parts. Process water, which constitutes 12 percent
of the gross water used by the industry, is used mainly for de-
greasing after machining operations, scale removal from metal stock
and cleaning before electroplating.
The manufacture of electrical connectors (Figure 3-263) is represen-
tative of this industry. The manufacture starts with pickling in
sulfuric acid to remove the scale on the metal stock. The electric-
al pin contacts are stamped, trimmed and finished. The bushings,
endbells, ferrules, coupling nuts and barrels are cut, turned and
threaded from bar stock on a lathe. Cutting oils are used in this
operation. These parts are then degreased and rinsed and treated
with a sodium carbonate solution at 3 percent concentration, followed
by a sodium phosphate solution treatment and then a sodium hydroxide
rinse solution for neutralization. The contacts are electroplated
and then rinsed and dried. The groumets and insulators are molded
from various plastics, rubbers or teflon materials depending on the
type of service for which the connector is designed. All the piece
parts are then assembled and the unit is inspected and packaged for
shipment.
3-674
-------
DRAFT
PRODUCTION DATA Electronic connectors
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 78
WITH LESS THAN 20 EMPLOYEES 12
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 16,100
VALUE ADDED BY MANUFACTURE $303.6 MILLION
VALUE OF SHIPMENTS $425.3 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 0
2 MECHANICAL MATERIAL REMOVAL 50
3 MATERIAL FORMING - METALS 50
4 PHYSICAL PROPERTY MODIFICATION 100
5 ASSEMBLY OPERATIONS 50
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS IQQ
7 MATERIAL COATING 50
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 50
WATER USE INCLUDES 3675, 3676, 3677, 3678, 3679
ANNUAL GROSS WATER USE 28.3
107.1
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
32
68
55
12
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 29
PERCENT OF DISCHARGED WATER TREATED 33
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-126
3-675
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Electronic Components Not
Elsewhere Classified
This segment includes establishments primarily engaged in manufactur-
ing electronic components, not elsewhere classified, such as receiving
antennas, printed circuits, switches, and wave guides. The major
products are:
Antennas, receiving: automobile, home,
portable
Attenuators
Circuit boards, television and radar:
electric - printed
Commutators, electronic
Constant impedance transformers
Cores, magnetic
Cryogenic cooling devices (cryostats,
etc.) for infra-red detectors, masers
Crystals and crystal assemblies, radio
Delay lines
Electronic circuits, except semicon-
ductor or solid state
Electronic tube parts, except glass
blanks
Ferrite electronic parts
Harness assemblies, for electronic use:
wire and cable
Headphones, radio
Hermetic seals, for electronic equip-
ment
Impedance conversion units, high fre-
quency
Loads, electronic
Magnetic recording tape
Microwave components
Oscillators, except laboratory type
Parametric amplifiers
Passive repeaters
Phonograph needle cartridges
Phonograph needles
Piezoelectric crystals
Power supplies, static: regulated, un-
regulated, variable frequency
Printed circuits
Pulse forming networks
Quartz crystals, for electronic appli-
cation
-------
UHMT I
Recording and playback heads, mag-
netic
Recording heads, for speech and musical
equipment
Rectifiers, electronic: except solid
state
Relays, for electronic use
Resonant reed devices, electronic
Rheostats, for electronic end products
Sockets, electronic tube
Solenoids for electronic applications
Step positioners for transmitting
equipment
Styli, phonograph record cutting
Switches, electronic applications
Switches, stepping
Tape, magnetic recording, including
paper type
Thick film circuits
Transducers, electrical
Tube retainers, electronic
Tube spacers, mica
Tube transformer assemblies used in
firing electronic tubes
Video triggers, except remote control
TV devices
Voice controls
Wave guides and fittings
Electronic components not elesewhere classified are produced by 1791
plants, averaging 64 workers each. Most of these plants (63 percent)
employ less than 20 workers. Additional production data are shown
in Table 3-127. As shown in Figure 3-264, the major products in this
category are printed circuits, crystals and filters, microwave compo-
nents and magnetic recording media. Steel, aluminum, copper, insulate<
wire and cable, castings and electronic components are the major raw
materials. The principal manufacturing operations are mechanical
material removal, chemical/electrochemical operations, material coat-
ing, and assembly operations.
Electronic components in this category are made by a wide range of
diverse manufacturing processes with the manufacture of printed cir-
cuit boards being by far the major product in this category. In
general, these circuit boards are made by drilling holes in a copper
clad board, applying a resist to those areas that are not to be etched
and then etching the board. Process water, which constitutes 12 per-
cent of the gross water used by the industry, is used mainly for
cleaning and rinse waters.
-------
DRAFT
The manufacture of printed circuit boards (Figure 3-265) is represen-
tative of the electronic components industry. First a copper clad
board is drilled then deburred, scrubbed and soaked clean. The board
is then dipped into ammonium persulfate and then sulfuric acid and
rinsed after each dip. Hydrochloric acid is applied, activated, and
accelerated. Electroless copper is then deposited and the board is
dipped into sulfuric acid and rinsed. A thick plate of copper is
applied next and the board is rinsed and dried in a blower. The re-
sist is applied and it is then soaked, cleaned and rinsed again. Then
the board is again dipped in acid and rinsed. If gold is to be used
as the etch resist, the board is nickel plated, rinsed, dipped in
acid and rinsed again. A gold strike is applied by plating and then
the board is gold plated. The copper is then etched and the resist
is removed and printed circuit board is rinsed and dried. The gold
from the plating solution is recovered and recycled.
3-680
-------
DRAFT
PRODUCTION DATA Electronic components, nee
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 662
WITH LESS THAN 20 EMPLOYEES 1129
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 113,900
VALUE ADDED BY MANUFACTURE $1895.7 MILLION
VALUE OF SHiPMENTS $3564.6 MILLION
4
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 5
2 MECHANICAL MATERiAL REMOVAL 57
3 MATERIAL FORMING - METALS 14
4 PHYSICAL PROPERTY MODIFICATION 24
5 ASSEMBLY OPERATIONS 81
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 67
7 MATERIAL COATING 33
8 ORE PROCESSING & REFINING 0
9 MOLDiNC & FORMING - NON-METALS 24
WATER USE INCLUDES 3675, 3676, 3677, 3678, 3679
ANNUAL GROSS WATER USE 28.3
107.1
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
32
68
55
12
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 29
PERCENT OF DISCHARGED WATER TREATED 33
NA NOT AVAILABLE
*Based or. Plant Data Collected
TABLE 3-127
3-681
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Storage Batteries
This segment includes establishments primarily engaged in manufactur-
ing storage batteries, and the products include:
Alkaline cell storage batteries
Lead acid batteries (storage
batteries)
Storage batteries
Storage batteries are produced by 208 plants, averaging 106 workers
each. Most of these plants (56 percent) employ more than 20 work-
ers. Additional production data are shown in Table 3-128. As shown
in Figure 3-266, 7 percent of the storage batteries produced are
automobile replacement batteries, 2 percent are original equipment
automobile batteries, 10 percent are nickel cadmium batteries, 2
percent are lead acid batteries for other than motor vehicles, and
79 percent are for other uses. Lead, purchased plastic cases,
litharge and sulfuric acid are the major raw materials. The prin-
cipal manufacturing operations are molding and forming, material
forming and assembly operations.
In general storage batteries are made by casting the plates out of
lead, spreading a lead oxide and sulfuric acid paste on the plates,
drying, assembling and adding the acid. Process water, ^which con-
stitutes 20 percent of the gross water used by the industry, is
used mainly for cleaning and rinsing. Unused sulfuric acid is also
a major source of waste.
The manufacture of lead-acid storage batteries (Figure 3-267) is
representative of the storage battery industry. First lead is cast
to form the grids. A paste is then made by mixing lead oxides with
sulfuric acid and water. This paste is spread onto the lead grids
to form plates which are cured and dried. The plates are then
stacked with a spacer material between them to form the battery cells.
At this point in the assembly, the operation varies for wet charged
and dry charged batteries. The wet charged battery cells are assembled
in a plastic or rubber case, interconnected, sealed, tested and filled
with sulfuric acid. An electrical charge is applied to the battery
terminals which converts the negative plates to lead sponge and the
positive .plates to lead peroxide. This operation, called forming,
completes the battery manufacture.
The dry charge batteries are shipped and stored without sulphuric
acid to extend the battery shelf life. For the dry charge battery,
the forming operation is accomplished by connecting the battery cells
3-684
-------
and immersing them in forming tanks containing sulfuric acid for the
actual forming. The cells are then removed, washed and assembled in
the battery case. Then they are tested, decorated and readied for
shipment. Some manufacturers of dry charged batteries are able to
conduct the forming operation with the cells in the battery case.
3-685
-------
DRAFT
PRODUCTION DATA Storage Batteries
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 117
WITH LESS THAN 20 EMPLOYEES 91
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 22,000
VALUE ADDED BY MANUFACTURE $474.3 MILLION
VALUE OF SHIPMENTS $959.6 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS*
1 CASTINGS MOLDING-METALS 90
2 MECHANICAL MATERIAL REMOVAL 20
3 MATERIAL FORMING - METALS 10
4 PHYSICAL PROPERTY MODIFICATION IQ
5 ASSEMBLY OPERATIONS 1QO
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 2Q
7 MATERIAL COATING IQ
*
8 ORE PROCESSING & REFINING 10
9 MOLDING & FORMING - NON-METALS IQ
WATER USE
ANNUAL GROSS WATER USE
6.9
26.1
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
41
59
54
20
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
36
35
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-128
3-686
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3-688
-------
Primary Batteries, Dry and Wet
This segment includes establishments primarily engaged in manufactur-
ing primary batteries, dry or wet. The products are:
Batteries, primary: dry or wet
Dry cell batteries, single and multiple cell
Primary Batteries, Dry and Wet, are produced by 49 plants, averaging
171 workers each. Most of these plants (65 percent) employ more than
20 workers. Additional production data are shown in Table 3-129.
As shown in Figure 3-268, 81 percent of the batteries produced in
this category are flashlight and radio dry cell batteries, 19 per-
cent are general purpose dry cells and less than 1 percent are wet
cells. Zinc and zinc based alloys and carbon and graphite products
are the major raw materials. The principal manufacturing operations
are material forming and assembly operations.
In general primary batteries, of which carbon zinc batteries are the
most common, are made by forming the container and inserting a liner.
The container is then filled with the depolarizer and the electrolyte.
The carbon rod is added next and the battery is sealed. Process watei
which constitutes 22 percent of the gross water used by the industry,
is used mainly for cleaning of raw metal stock prior to assembling
and charging.
The manufacture of carbon-zinc batteries (Figure 3-269) is represen-
tative of the primary battery industry. The container is drawn or
stamped from zinc sheet. The paperboard liner is coated with a paste
containing HgC12_ and inserted in the zinc container. The depolarizer
containing Mn02_ and carbon black and the electrolyte consisting of
NH4C1 and ZnCl2_ are added next. The carbon rod is inserted in the
middle of the battery and a washer made out of paperboard is added
to support the carbon rod. The cell is then sealed with an asphalt
compound and the top and bottom covers are formed from sheet steel
and the top and case are crimped over the container. The batteries
are then tested and packed.
3-689
-------
DRAFT
PRODUCTION DATA Primary Batteries, Dry and Wet
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 32
WITH LESS THAN 20 EMPLOYEES 17
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 8,400
VALUE ADDED BY MANUFACTURE $221.9 MILLION
VALUE OF SHIPMENTS $348.3 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 40
2 MECHANICAL MATERIAL REMOVAL 20
3 MATERIAL FORMING - METALS 40
4 PHYSICAL PROPERTY MODIFICATION 20
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 40
7 MATERIAL COATING 20
8 ORE PROCESSINGS REFINING 0
9 MOLDING & FORMING — NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE 0.9 BILLION GALLONS
3.4 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 57
REUSED WATER AS PERCENT OF GROSS USE 33
PERCENT OF ESTABLISHMENTS REUSING WATER 64
PROCESS WATER AS PERCENT OF GROSS USE 22
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 77
PERCENT OF DISCHARGED WATER TREATED Q
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-129
3-690
-------
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3-691
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Radiographic X-ray, Fluoroscopic X-ray,
Therapeutic X-ray, and Other X-ray Apparatus
and Tubes; Electromedical and Electrotherapeutic
Apparatus
This segment includes establishments primarily engaged in manufactur-
ing radiographic X-ray, fluoroscopic X-ray, and therapeutic X-ray
apparatus and tubes for medical, industrial, research and control
applications. This industry also includes establishments primarily
engaged in manufacturing electromedical and electrotherapeutic
apparatus except electrotherapeutic lamp units for ultra-violet
and infra-red radiation (Industry 3641). The major products are:
Arc lamp units, electrctherapeutic:
except infra-red and ultra-violet
Cardiographs
Electrocardiographs
Electroencephalcgraphs
Electromedical apparatus
Electromyographs
Fluoroscopes
Fluoroscopic X-ray apparatus and tubes
Lamps, X-ray
Phonocardiographs
Radiographic X-ray apparatus and tubes:
medical, industrial, and research
Radium equipment
Therapeutic X-ray apparatus and tubes: for
medical, industrial, research
X-ray apparatus and tubes: for medical,
industrial, research, and control
X-ray generators
X-ray apparatus and tubes are produced by 98 plants, averaging 108
workers each. Half of these plants employ mere than ?0 workers.
Additional production data are shown in Table 3-130. As showr in
Figure 3-270, 23 percent of the products in this category ere
medical, electronic equipment and 77 percent is X-ray equipment.
Steel, copper, nickel, aluminum,, glass, ceramic compounds, solders
and electronic components are the major raw materials. The
3-693
-------
principal manufacturing operations are mechanical material removal,
material coating, material forming (metals) and assembly operations.
In general X-ray apparatus is made by metal" forming and machining
of the cabinet and then installation and wiring of the electrical
components and X-ray tube. The X-ray tubes are made in essentially
the same manner as electron tubes. Process water is used mainly
for cleaning of the components at various stages of manufacture.
Air scrubbing in the painting booths for the painting of the cabinets
also uses process water.
The manufacture of X-ray tube apparatus (Figure 3-271) is repre-
sentative of this industry. The metal parts are machined then
degreased and cleaned and fired in a furnace. The glass parts are
cleaned and then worked into the required shapes. Both the metal
and glass parts are then assembled to form the tube and the tube
is exhausted of all gases, cleaned, tested and electroplated.
The circuit boards are fabricated and etched as described for
Electronic Components. Electrical components (resistors, capacitor,
etc.) are inserted into the board and the board is dip soldered.
The metal cabinet and case is formed by metal shearing, bending
and welding. Holes are drilled to mount the components, then
the cabinet is painted and the components, subassemblies and the
circuit boards mounted. Finally, the X-ray tube is installed and
the unit is tested.
3-694
-------
DRAFT
Radiographic X-ray, Fluoroscopic X-ray, Therapeutic X-ray,
PRODUCTION DATA aricj other X-ray Apparatus and Tubes; Electro-medical and
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 49
WITH LESS THAN 20 EMPLOYEES 49
NUMBER OF EMPLOYEES ALL ESTABLSSHMENTS 10,600
VALUE ADDED BY MANUFACTURE $2£3.8 MILLION
VALUE OF SHIPMENTS $429.0 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTINGS MOLDING-METALS NA
2 MECHANICAL MATERIAL REMOVAL NA
3 MATERIAL FORMSNG - METALS NA
4 PHYSICAL PROPERTY MODIFICATION NA
5 ASSEMBLY OPERATIONS NA
6 CHEMICAL-ELECTROCHEMICAL OPE ATIONS NA
7 MATERIAL, COATING NA
8 ORE PROCESSING & REFINING NA
9 MOLDING a FORM ING-NON-METALS NA
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION L5TERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATZTR AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
NA
NA
NA NOT AVAILABLE
*BASED ON PLANT DATA COLLECTED
TABLE 3-130
3-695
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3-697
-------
urcAr i
Electrical Equipment for Internal
Combustion Engines
This segment includes establishments primarily engaged in manufactur-
ing electrical equipment for internal combustion engines. Important
products of this industry include:
Alternators, automotive
Armatures, automobile
Automotive electrical equipment
Battery cable wiring sets for internal
combustion engines
Battery charging generators, automobile
and aircraft
Coils, ignition: automotive
Generators, aircraft and automotive
Harness, wiring for motor vehicles:
ignition
Ignition cable sets or wire assemblies
for internal combustion engines
Ignition systems, high frequency
Motor generator sets, automotive
Motors, starting: automotive and aircraft
Spark plugs, for internal combustion engines
Voltage regulators, automotive
Electrical equipment for internal combustion engines are produced by
284 plants, averaging 202 workers. About half of these plants (49
percent) employ more than 20 workers. Additional production data
are shown in Table 3-131. As shown in Figure 3-272, 60 percent of
the products produced in this category are spark plugs, 2 percent
are battery charging generators, 2 percent are ignition harnesses
and cable sets, 1 percent are cranking motors and 35 percent is
miscellaneous electrical equipment for internal combustion engines.
Steel, insulated wire and cable, copper, cluminum, castings, primary
metals and bearings are the major raw materials. The principal manu-
facturing operations are mechanical material removal, material form-
ing and material coating.
Electrical equipment for internal combustion engines is made by a
wide range of diverse manufacturing processes. Cranking motors and
alternatbrs can be considered to be representative. For these, the
stator and the rotor are formed and wound. The body frame and end
bells are cast and machined and the unit is assembled. Process
water, which constitutes 21 percent of the gross water used by the
industry, is used mainly for cleaning and pickling. Air scrubbers
at painting booths (for painted hardware) are also a major source of
wastewater.
3-698
-------
DRAFT
The manufacture of starting motors (Figure 3-273) is representative
of this industry. Silicon steel stock is first cleaned in a pick-
ling solution. The laminations are then formed and insulated. They
are then sheared into strips and cut into circles. The form for the
field windings is blanked out and notched. The laminations are then
stacked and tack welded to form the armature. The armature and field
are then wound, dipped in a lacquer and baked.
The body frame is cast and machined. The end bells are cast, turned
and machined and then cleaned in a pickling solution. The pieces are
then primed and painted. The armature shaft is machined, and chamber*
and the keyway is cut. It is then pressed into the armature and
balanced. All of these parts are then assembled along with purchased
carbon brushes and the starting motor is cleaned and tested.
T-fiQQ
-------
DRAFT
PRODUCTION DATA Electrical Equipment for Internal Combustion EnaJnes
NUMBER OF ESTABLISHMENTS. WITH MORE THAN 20 EMPLOYEES 138
WITH LESS THAN 20 EMPLOYEES 146
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 57,400
VALUE ADDED BY MANUFACTURE $1241.3 MILLION
VALUE OF SHIPMENTS $2095.1 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 0
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 80
4 PHYSICAL PROPERTY MODIFICATION 40
5 ASSEMBLY OPERATIONS 80
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 40
7 MATERIAL COATING 60
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 100
WATER USE
ANNUAL GROSS WATER USE 8
30.3
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
61
39
PERCENT OF ESTABLISHMENTS REUSING WATER 88
PROCESS WATER AS PERCENT OF GROSS USE 21
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 56
PERCENT OF DISCHARGED WATER TREATED 2.1
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-131
3-700
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DRAFT
Electrical Machinery, Equipment, and Supplies,
Not Elsewhere Classified
This segment includes establishments primarily engaged in manufactui
ing electrical machinery, equipment, and supplies, not elsewhere
classified, such as appliance and extension cords, bells and chimes,
and insect traps. The major products are:
Appliance cords for electric irons,
grills, waffle irons, etc. - mfpm
Bells, electric
Chimes, electric
Christmas tree lighting sets, electric
Clothing, electrically heated
Door opening and closing devices, ex-
cept photoelectric cell operated
Electric fence chargers
Electric lamp (bulb) parts
Electrodes, cold cathode fluorescent
lamp
Extension cords, made from purchased
insulated wire
Filaments, for electric lamps
Fly traps, electrical
Gongs, electric
Grids, electric
Lamp (bulb) parts, electric
Lamps, insect: electric
Lead-in wires, electric lamp: made from
purchased wire
Logs, fireplace: electric
Ornaments, Christmas tree: electric
Supports and filaments, for electric
lamps
Trouble lights, made from purchased
materials
Electrical machinery is produced by 992 plants, averaging 20 work-
ers each. Most of these plants (81 percent) employ less than 20
workers each. Additional production data are shown in Table 3-132
and Figure 3-274. Forty-one percent of the dollar value of the
products produced in this industry is from the manufacture of light
bulbs and components and other electrical products. Another 41 per-
cent is from appliance wire and cord and flexible cord sets, and 18
percent is from other electrical machinery. Steel, insulated wire
and cable, copper, and aluminum are the major raw materials. The
3-703
-------
principal manufacturing operations are mechanical material removal,
material forming (metals) and material coating.
In general, electrical machinery is made by a wide range of diverse
manufacturing processes. Process water is used for various purposes
throughout this industry with most of it used for cleaning and
electroplating rinses.
The manufacture of extension cords (Figure 3-275) is representative
of the electrical machinery industry. Insulated wire is purchased,
cut to length and the ends stripped of their insulation. The leads
are twisted and tinned. The metal prongs are manufactured by stamp-
ing them out of metal stock, bending them to shape, and electroplating
them if needed. This plating is usually followed by a rinse. The
tinned leads are then inserted into the metal contacts and either
soldered or crimped into place. A plastic plug shell is molded
around the prongs. The other end of the cord is finished off in
a similar manner and the cord is inspected and readied for shipment.
3-704
-------
DRAFT
PDr,n.,r-rir,M naTA Electrical Machinery, Equipment, and Supplies, Not
PRODUCTION DATA Flsewhere classified
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 187
WITH LESS THAN 20 EMPLOYEES 805
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 20,100
VALUE ADDED BY MANUFACTURE $282.7 MILLION
VALUE OF SHIPMENTS $535.0 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 0
2 MECHANICAL MATERIAL REMOVAL 0
3 MATERIAL FORMING - METALS 50
4 PHYSICAL PROPERTY MODIFICATION 50
5 ASSEMBLY OPERATIONS 50
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 50
7 MATERIAL COATING 0
8 ORE PROCESSING & REFINING 50
9 MOLDING & FORMING - NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE JJA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-132
3-705
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DRAFT
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Motor Vehicles and Passenger Car Bodies
This segment includes establishments primarily engaged in manufactur-
ing or assembling complete passenger automobiles, trucks, commercial
cars and buses (except trackless trolleys), and special purpose
motor vehicles. This industry also includes establishments primarily
engaged in manufacturing chassis or passenger car bodies. The
principal products are:
Ambulances (motor vehicles)
Amphibian motor vehicles
Assembling complete automobiles, trucks,
commercial cars, and buses
Automobiles
Bodies, passenger automobile
Brooms, powered (motor vehicles)
Cars, armored
Chassis, motor vehicle
Fire department vehicles (motor vehicles)
Flushers, street (motor vehicles)
Hearses (motor vehicles)
Mobile lounges (motor vehicle)
Motor buses, except trackless trolley
Motor trucks, except off-highway
Motor vehicles, including amphibian
Patrol wagons (motor vehicles)
Personnel carriers (motor vehicles)
Reconnaissance cars
Road oilers (motor vehicles)
Scout cars (motor vehicles)
Snowplows (motor vehicles)
Station wagons (motor vehicles)
Street sprinklers and sweepers (motor vehicles)
Taxicabs
Tractors, truck: for highway use
Universal carriers, military
3-708
-------
DRAFT
Motor vehicles and passenger car bodies are produced by 231 plants,
averaging 1004 workers each. Most of these plants (52 percent)
employ more than 20 workers. Additional production data are shown
in Table 3-133. As shown in Figure 3-276, steel (stainless, alloy,
and carbon), copper, copper alloy, aluminum, and aluminum alloy in
the form of sheet, bar, plate and other various shapes are the
principal raw materials. In addition, metal powders, fabrics,
plastic film and sheets, resins and various coatings are also
used. The principal manufacturing operations are mechanical
material removal, material forming, material coating, and assembly
operations.
This industry primarily encompasses assembly of completed motor vehic]
and fabrication of chassis and bodies. As such, component parts
are generally bought or made and assembled to produce the completed
motor vehicle. The bodies and frames are made by forming metal
and plastic stock and joining component parts. Process water,
which constitutes 8 percent of the gross water used by the industry,
is used mainly for rinsing and painting operations.
The assembly of automobiles and the manufacture of automobile frames
are representative of the motor vehicle and passenger car bodies
industry. A typical operation for assembling automobiles is shown
in Figure 3-277, while Figure 3-278 shows a typical operation for mant
facturing an automobile frame. The manufacture of automobile frames
as shown in Figure 3-278, starts with shearing or cutting metal sheet
stock to size. The sheet metal is then lubricated with a water-oil
emulsion and stamped, blanked, punched and formed. When the pieces
are formed they are fastened together by welding, brazing, and
mechanical fasteners. Some of the welding operations use water as
a cooling agent. After fastening the frame together, it is cleaned
and finally painted using a spray booth with water curtains. The fran
is then inspected and aligned.
The actual assembly of automobiles is essentially a dry operation
as the block diagram indicates. However, water is used for
water curtains in spray paint booths, for testing and for washing
the finished product. This assembly basically proceeds along two
parallel paths, one involving the frame, motor and suspension system
and another for the body. These two lines meet for a final line
where the body, frame, radiator, gas tank, hood, and front panels
are joined together. Prior to this final line assembly, the assem-
bled body is conversion coated and painted. In the final assembly
line, the upholstery and interior are assembled into the automobile,
including seats, rug, wiring and dashboard components. The assembled
automobile is then tested including a body water check. Final in-
spection follows testing and then the car is washed.
3-709
-------
DRAFT
PRODUCTION DATA Motor vehicles and car bodies
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 120
WITH LESS THAN 20 EMPLOYEES HI
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 340,400
VALUE ADDED BY MANUFACTURE $12 , 026 . 4 MILLION
VALUE OF SHIPMENTS $42,970.1 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING& MOLDING - METALS 29
2 MECHANICAL MATERIAL REMOVAL 43
3 MATERIAL FORMING - METALS 29
4 PHYSICAL PROPERTY MODIFICATION 29
5 ASSEMBLY OPERATIONS 86
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 71
7 MATERIAL COATING 100
8 ORE PROCESSINGS REFINING 0
k
9 MOLDING & FORMING- NON-METALS 14
WATER USE
ANNUAL GROSS WATER USE 242.7 BILLION GALLONS
918.6 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 13%
REUSED WATER AS PERCENT OF GROSS USE 87%
PERCENT OF ESTABLISHMENTS REUSING WATER 94%
PROCESS WATER AS PERCENT OF GROSS USE 6%
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 12%
PERCENT OF DISCHARGED WATER TREATED 13%
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-133
3-710
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Truck and Bus Bodies
This segment includes establishments primarily engaged in manufactur-
ing truck and bus bodies, for sale separately or for assembly on pur-
chased chassis. The products are:
Ambulance bodies
Automobile wrecker-truck body
Bodies, dump
Bus bodies (motor vehicles)
Cabs, for agricultural tractors
Cabs, for industrial trucks
Hearse bodies
Truck, beds
Truck bodies, motor vehicle
Truck cabs, for motor vehicles
Truck tops
Truck and bus bodies are produced by 762 plants averaging 55 work-
ers each. Most of these plants (56 percent) employ less than 20
workers. Additional production data are shown in Table 3-134. The
raw materials and products are shown in Figure 3-279. As can be
seen from this data, aluminum, steel (stainless, alloy and carbon),
copper, copper alloy and aluminum alloy are used in the form of
sheet, bar, plate, and other various shapes. In addition, metal
powders, impregnated and laminated fabrics, plastic film, and
sheets, resins and various coatings are used. The principal manu-
facturing operations for truck and bus bodies are mechanical material
removal, material forming, physical property modification, electro-
chemical processing, assembly operations, material coatings and
plastics molding.
The outer structure of truck and bus bodies is manufactured by
forming sheet metal. Interior trim including seats, dashboards,
flooring, etc. is assembled to this outer shell to complete fabri-
cation of the body. Process water is used mainly for cooling and
for cleaning rinses.
The manufacture of truck bodies is representative of the truck and
bus bodies manufacturing industry. A typical operation for manu-
facturing truck bodies is shown in Figure 3-280. Raw material in
3-714
-------
DRAFT
the form of sheet metal is sheared before being lubricated with a
water-oil emulsion before blanking and stamping. Following stamping,
piercing is performed and then forming in dies using a forming
lubricant. These formed parts are washed and, where required, sub-
assembled. Then these pieces are conversion coated and painted or
plated. Painting may be repeated several times. Inspection and
alignment (where necessary) are done on the subassembled pieces.
During the plating and painting process water is used to clean,
wash and rinse the pieces. Water is also used in paint spray booths
for water curtains. Raw plastic is molded and trimmed to form many
finished plastic accessories. Finished seats and upholstery are cut
from fabric, sewn together, padded and attached to a frame. The
accessories, seats, shell and metal parts are joined, which is done
by welding, brazing, adhesion bonding or mechanical fasteners.
The finished bodies are then baked and final assembly is initiated tc
add trim, glass, and instruments (these vary according to the parti-
cular product). After final assembly, the bodies are inspected and
assembled to purchased chassis or shipped out and sold to be
assembled to frames elsewhere.
-------
DRAFT
PRODUCTION DATA Truck an(j bus bodies
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 336
WITH LESS THAN 20 EMPLOYEES 426
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 42,000
VALUE ADDED BY MANUFACTURE $ 631.2 MILLION
VALUE OF SHIPMENTS $1512.8 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 25
2 MECHANICAL MATERIAL REMOVAL 50
3 MATERIAL FORMING - METALS 100
4 PHYSICAL PROPERTY MODIFICATION 50
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 25
7 MATERIAL COATING 100
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 25
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3--134
3-716
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DRAFT
Motor Vehicle Parts and Accessories
This segment includes establishments primarily engaged in manufactur-
ing motor vehicle parts and accessories, but not engaged in manufartui
ing complete motor vehicles or passenger car bodies. The products ere
Acceleration equipment, motor vehicle
Air brakes, motor vehicle
Automotive wiring harness sets, other than
ignition
Axle housings and shafts, motor vehicle
Axles, motor vehicle
Bearings, motor vehicle: except ball and roller
Brake drums
Brakes and brake parts, motor vehicle
Bumpers and bumnerettes, motor vehicle
Camshafts, motor vehicle
Choker rods, motor vehicle
Cleaners, air: motor vehicle
Connecting rods, motor vehicle engine
Control equipment, motor vehicle: acceleration
mechanisms, governors, etc.
Crankshaft assemblies, motor vehicle
Cylinder heads, motor vehicle
Defrosters, motor vehicle
Differentials and parts, motor vehicle
Directional signals, motor vehicle
Drive shafts, motor vehicle
Engines and parts, except diesel: motor vehicle
Exhaust systems and parts, motor vehicle
Fifth wheels
Filters: oil, fuel, and air - motor vehicle
Frames, motor vehicle
Fuel pumps, motor vehicle
Fuel systems and parts, motor vehicle: gas tanks,
fuel pipes, and manifold
Gas tanks, motor vehicle
Gears, motor vehicle
Governors, motor vehicle
Heaters, motor vehicle
Hoods, motor vehicle
Horns, motor vehicle
Hydraulic fluid power pumps, for automotive steering
mechanisms
Instrument board assemblies, motor vehicle
Lubrication systems and parts, motor vehicle
Manifolds, motor vehicle
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Motor vehicle engine rebuilding, on a factory
basis
Motor vehicle parts and accessories.(except motor
vehicle stampings)
Mufflers, exhaust: motor vehicle
Oil strainers, motor vehicle
Pipes, fuel: motor vehicle
Power transmission equipment, motor vehicle
Radiators and radiator shells and cores, motor
vehicle
Rear axle housings, motor vehicle
Rebuilding motor vehicle engines and transmissions,
on a factory basis
Rims, wheel: motor vehicle
Sanders, motor vehicle safety
Shock absorbers, motor vehicle
Steering mechanisms, motor vehicle
Third axle attachments or six-wheel units for motor
vehicles
Tie rods, motor vehicle
Tire valve cores
Tops, motor vehicle: except stamped metal
Transmission housings and parts, motor vehicle
Transmissions, motor vehicle
Universal joints, motor vehicle
Vacuum brakes, motor vehicle
Wheels, motor vehicle
Windshield frames, motor vehicle
Windshield wiper systems, all types
Winterfronts, motor vehicle
Wiring harness sets (other than ignition) automotive
Motor vehicle parts and accessories are produced by 2083 plants,
averaging 193 workers each. Most of these plants (55 percent)
employ less than 20 workers. Additional production data are shown
in Table 3-135. As shown in Figure 3-281, steel (alloy, stainless
and carbon), aluminum, copper, copper alloy and aluminum alloy
in the form of sheet, bar, plate, and other various shapes are
the major raw materials. In addition, powders (jcast or forged) ,
impregnated and laminated fabrics, plastic film Sand sheets, resins
and various coatings are used. The principal manufacturing oper-
3-720
-------
DRAFT
ations are mechanical material removal, material forming, electro-
chemical processing, physical property modification, and material
coating.
The diversity of products in the motor vehicle parts and accessories
industry results in the utilization of all of the above process types
with particular processes and sequence depending on the specific
product. Process water, which constitutes about 13 percent of the
gross water used by the industry, is used mainly for contact cooling.
The manufacture of engines and associated parts is representative
of the motor vehicle parts and accessories industry. A typical
operation for manufacturing engines and engine parts is shown in
Figure 3-282. Engine blocks, rocker arms and heads are made by
sand casting aluminum, or iron. Non-contact cooling water
is used to cool the furnaces in the foundry and water scrubbers
are used to clean the air. Parts such as the crankshaft, camshaft,
and connecting rods are forged (hammer or press), cleaned and then
machined. Sheet metal parts including oil pans, fans, and rocker arn
covers are stamped using a water-oil emulsion lubricant.
Cast and forged parts (all or some) are then machined where required
by milling, drilling, boring, grinding, tapping and honing. Those
that are milled, drilled, bored and ground are all lubricated with
a water-oil emulsion during the operation. Parts that are honed are
lubricated with honing oil and tapped parts are lubricated with
cutting oil. All parts are cleaned after the machining operations
and some are also heat treated and cleaned again. After the
machining, heat treating and cleaning have been completed, the cast,
forged or stamped parts may be conversion coated or plated before
assembly. When the assembly is completed the engine is tested (where
contact cooling water is used), cleaned, painted and shipped to the
final automobile assembly area.
-------
DRAFT
PRODUCTION DATA Motor Vehicle Parts and Accessories
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 920
WITH LESS THAN 20 EMPLOYEES 1163
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 401,000
VALUE ADDED BY MANUFACTURE $9146.9 MILLION
VALUE OF SHIPMENTS $18285.4 MILLION
a
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & FOLDING — METALS 17
2 MECHANICAL MATERIAL REMOVAL 78
3 MATERIAL FORMING — METALS 61
4 PHYSICAL PROPERTY MODIFICATION 50
5 ASSEMBLY OPERATIONS 78
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 56
7 MATERIAL COATING 76
8 ORE PROCESSING & REFINING 6
9 MOLDING &FORM:NG-NON-METALS 6
WATER USE
ANNUAL GROSS WATER USE
673.7
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
59
41
PERCENT OF ESTABLISHMENTS REUSING WATER 94
PROCESS WATER AS PERCENT OF GROSS USE 12.6
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 55
PERCENT OF DISCHARGED WATER TREATED 10
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-135
3-722
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DRAFT
Truck Trailers
This segment includes establishments primarily engaged in manufacturinc
ing truck trailers, truck trailer chassis for sale separately, detach-
able trailer bodies (cargo containers) for sale separately, and
detachable trailer (cargo container) chassis, for sale separately.
Products in this SIC include:
Bus trailers, tractor type
Demountable cargo containers
Motor truck trailers
Semitrailers for missile transportation
Semitrailers for truck tractors
Trailers or vans for transporting horses
Trailers, motor truck
Truck trailers
Truck trailers are produced by 244 plants, averaging 100 workers
each. Most of these plants (55 percent) employ more than 20
workers. Additional production data are shown in Table 3-136.
The raw materials are shown in Figure 3-283, and include sheet,
bar, plate and other various shapes of aluminum, aluminum alloy,
steel (carbon, alloy and stainless), copper and copper base alloy.
In addition, various coatings are also used. The principal manu-
facturing operations are mechanical material removal, assembly
operations, material forming (metals), and material coating.
This industry primarily encompasses manufacture of truck trailers.
These trailers are usually made from formed metal or plastic stock
sections that are joined together with rivets, bolts, or by weld-
ing. Process water is not used in this industry.
The manufacture of truck trailers is representative of this
industry. A typical operation for manufacturing truck trailers
is shown in Figure 3-284. The manufacture is started by shearing
sheet stock to length and then blanking, punching and forming it
to the desired shape. This process forms the finished panels for
the side and top of the trailer. Rails are bought and either
welded, brazed, or mechanically fastened together to form the
frame that supports the trailer. The suspension, wheels, drums,
etc. are then assembled to the frame. After this, upright rails and
top rails are welded, brazed or assembled to the frame, and the side
panels are then riveted or welded to the rails. After the side
panels are attached, the roof is welded or riveted in place and the
interior of the trailer is lined with plywood using mechanical
fasteners or adhesive bonding. Next, an oak plank floor is laid in
place and fastened down and the doors are hung. The outer skin of
the trailer is then painted.
-------
DRAFT
PRODUCTION DATA Truck trailers
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 135
WITH LESS THAN 20 EMPLOYEES 109
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 24,500
VALUE ADDED BY MANUFACTURE $ 408.5 MILLION
VALUE OF SHIPMENTS $1103 . 7 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 0
2 MECHANICAL MATERIAL REMOVAL 34
3 MATERIAL FORMING - METALS 100
4 PHYSICAL PROPERTY MODIFICATION 0
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 67
7 MATERIAL COATING 100
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING-NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE .4
1.5
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
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PERCENT OF ESTABLISHMENTS REUSING WATER 33
PROCESS WATER AS PERCENT OF GROSS USE 0
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 75
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-136
3-726
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DRAFT
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3-728
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DRAFT
Aircraft
This segment includes establishments primarily engaged in manufacturi
or assembling complete aircraft. This industry also includes es-
tablishments primarily engaged in research and development on air-
craft or in factory-type aircraft modification on a contract or
fee basis. The products are:
Aircraft
Airplanes, fixed or rotary wing
Airships
Autogiros
Balloons (aircraft)
Dirigibles
Gliders (aircraft)
Helicopters
Aircraft are produced by 167 plants, averaging 1387 workers each.
Most of these plants (51 percent) employ more than 20 workers.
Additional production data are shown in Table 3-137. The raw
materials and products are shown in Figure 3-285. Major raw
materials include sheet, bar, plate and other various shapes made
of aluminum, aluminum alloy, steel (alloy, stainless, and carbon),
titanium, titanium alloy, copper, copper alloy, and nickel alloy.
In addition, various coatings are also used. The principal manu-
facturing operations are mechanical material removal, physical
property modification, material forming, assembly operations, and
material coating, and plastic molding.
This industry primarily encompasses manufacture and assembly of com-
plete aircraft. As such, component parts are generally bought or
made inhouse and then assembled. In general, complete aircraft bodiei
and wings are made by forming sheet metal, treating and joining to
structural members and painting the assembly. To this are added
the major components and subassemblies such as engines, landing gear,
interior trim, controls, etc. Process water is used mainly for
rinsing and cooling during machining operations. Rinsing follows
chemical milling, anodizing, conversion coating, heat treating,
plating and machining of parts.
The assembly of airplanes and the manufacture of associated sheet
metal assemblies are representative of the aircraft industry. A
typical operation for assembling aircraft is shown in Figure 3-286.
-------
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The assembly of airplanes is initiated with the fabrication of the
frame. This is done by rolling and bending sheet stock using a
forming oil. The frame parts are then cleaned, heat treated and
finish bent. After the second bending, the parts are again cleaned
and heat treated. Cutting the frame pieces to size and removing
the burrs follows, after which the pieces are anodized, assembled and
painted to complete the frame. Major parts such as the engines
and landing gear, etc. are attached to the frame by welding,
brazing or by mechanical fasteners. The assembly is then ready for
the skin which is seam welded or riveted to the frame. The interior
is outfitted with guidance systems, seats, steering assemblies etc.
Final painting and decorative lettering is then applied.
3-730
-------
DRAFT
DATA
Aircraft
DUMBER OF ESTABLISHMENTS, WITH MORE THAN 2C EMPLOYEES S6
WITH LESS THAN ?C EMPLOYEES tl
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 231,700
VALUE ADDED BY MANUFACTURE $50f(4.4 MILLiON
VALUE OF SHIPMENTS $£7'/4.7 M'LLION
PERCENT OF ESTABLISHMENTS (.'SING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING 8: MCLDING - METALS 40
2 MECHANICAL MATERIAL REMOVAL 90
3 MATERIAL FORMING - METALS 8G
4 PHYSICAL PROPERTY MODIFICATION 80
5 ASSEMBLY OPERATIONS 9C
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS IOC
7 MATERIAL COATING 9C
8 ORE PROCESSING ft REFINING 0
9 MOLDING & FORMING-NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PEPCFNT OF ESTABLISHMENTS REUSING WATER TW
PROCESS WATER AS PERCENT OF GROSC JSE '•tf-
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS,USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3- 137
-------
DRAFT
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-------
DRAFT
Aircraft Engines and Engine Parts
This segment includes establishments primarily engaged in manufacturing
aircraft engines and engine parts. Research and development on air-
craft engines is also included in this industry. The principal
products are:
Air scoops, aircraft
Aircraft engine starting vibrators
Aircraft engines and engine parts, in-
ternal combustion and jet propulsion
Cooling systems, aircraft engine
Engine heaters, aircraft
Engine mount parts, aircraft
Exhaust systems, aircraft
External power units, for hand inertia
starters, aircraft
Jet assisted takeoff devices (JATO)
Lubricating systems, aircraft
Pumps, aircraft engine
Rocket motors, aircraft
Starters, aircraft: nonelectric
Turbines, aircraft type
Turbo-superchargers, aircraft
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Aircraft engine and engine parts are produced by 229 plants, averaging
456 workers each. Most of these plants (67 percent) employ more than
20 workers. Additional production date is shown in Table 3-138. The
raw materials and products are shown in Figure 3-287, Aluminum,
aluminum alloy, steel (carbon, stainless, and alloy) titanium,
titanium alloy, copper, copper alloy and nickel alloy are the major
raw materials and are used in the form of sheet, bar, plate and other
various shaper. In addition x'arious coatings, adhesives, paints and
solvents are used. The principal manufacturing operations are
mechanical material removal, material forming (metals), physical
property modification, chemical/electrochemical operations, material
coating and assembly operations.
Because of the diversity of parts in this industry, no single product
discussion covers the whole field. Engines are made from many piece
parts, which are made inhouse or bought and then assembled to form the
finished engine. Process water, which constitutes 35 percent of the
gross water used by the industry, is used mainly for rinsing and cooling,
3-734
-------
DRAFT
The water used is associated with chemical milling, anodizing, heat
treating, conversion coating, plating and washing of the lubricants,
chemicals, solvents, salts, etc. following these operations.
The manufacture of aircraft jet engines is representative of the
aircraft engine and engine parts industry. A typical operation for
manufacturing aircraft jet engine parts and assembling them into an
engine is shown in Figure 3-288. Initially, raw material stock is
machined by milling, drilling, boring, and grinding using a water
oil emulsion. Honing is also done and uses a honing lubricant.
Chemical/electrochemical machining operations are also performed
as necessary in fabricating piece parts. In addition, electron
beam and electrodischarge machining are used which are dry processes.
Many of the fabricated piece parts are next polished, buffed or tumble
and then heat treated. After heat treating, parts are pickled to re-
move scale and then shot peened.
Subassemblies are fabricated next by welding, brazing and mechanically
fastening piece parts. After this, etching is done as required. The
piece parts and subassemblies are then conversion coated before paint-
ing or the parts may be anodized or plated. The particular final
coating depends upon the final application of each part. The finished
parts and subassemblies are then assembled into the final product
using mechanical fasteners, welding or brazing. The finished assembly
is then calibrated, inspected, tested and shipped.
-------
DRAFT
PRODUCTION DATA Aircraft engines and engine parts
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 153
WITH LESS THAN 20 EMPLOYEES 76
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 104,400
VALUE ADDED BY MANUFACTURE $2081.9 MILLION
VALUE OF SHIPMENTS $3633.7 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING--METALS 40
2 MECHANICAL MATERIAL REMOVAL 80
3 MATERIAL FORMING - METALS 40
4 PHYSICAL PROPERTY MODIFICATION 60
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPE RATIONS 100
7 MATERIAL COATING 100
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE 155.9 BILLION GALLONS
590 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 65
REUSED WATER AS PERCENT OF GROSS USE 35
PERCENT OF ESTABLISHMENTS REUSING WATER 78
PROCESS WATER AS PERCENT OF GROSS USE 3
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 61
PERCENT OF DISCHARGED WATER TREATED 2
NA NOT AVAILABLE *Based on Plant Data Collected
TABLE 3-138
3-736
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DRAFT
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DRAFT
Aircraft Parts and Auxiliary Equipment,
Not Elsewhere Classified
This segment includes establishments primarily engaged in manufacturing
aircraft parts and auxiliary equipment, not elsewhere classified.
Research and development on aircraft parts is included in this
industry. The products are:
Accumulators, aircraft propeller
Actuators, aircraft: mechanical, electrical,
and hydraulic
Adapter assemblies, hydromatic propeller
Ailerons, aircraft
Aircraft armament, except guns
Aircraft arresting device system
Aircraft assemblies, subassemblies, and parts,
except engines
Aircraft body assemblies and parts
Aircraft power transmission equipment
Aircraft propeller parts
Airframe assemblies, except for guided missiles
Airplane brake expanders
Alighting assemblies (landing gear) , aircraft
Beaching gear, aircraft
Blades, aircraft propeller: metal or wood
Bomb racks, aircraft
Brakes, aircraft
Chaffing dispensers, aircraft
Controls: hydraulic and pneumatic, aircraft
Countermeasure dispensers, aircraft
De-icing equipment, aircraft
Dive brakes, aircraft
Dusting and spraying equipment, aircraft
Dynetric balancing stands, aircraft
Elevators, aircraft
Empennage (tail) assemblies and parts, aircraft
Fins, aircraft
Flaps, aircraft wing
Fluid power and control components, aircraft
Fuel tanks, aircraft: including self-sealing
Fuselage assemblies, aircraft
Gears, power transmission: aircraft
Governors, aircraft propeller feathering
Hubs, aircraft propeller
Hydraulic pumps, valves, and cylinders: aircraft
Instrument panel mockups: aircraft training units
-------
DRAFT
Landing gear, aircraft
Landing skis and tracks, aircraft
Link trainers (aircraft training mechanisms)
Nacelles, aircraft
Oleo struts, aircraft
Oxygen systems, far aircraft
Panel assemblies (hydromatic propeller test stands),
aircraft
Pontoons, aircraft
Power transmission equipment, aircraft
Propeller alining tables
Propellers, variable and fixed pitch: and parts -
aircraft
Pumps, propeller feathering
Pefueling equipment, airplane: for use in flight
Roto-blades for helicopters
Rudders, aircraft
Seat ejector devices, aircraft
Spinners, aircraft propeller
Stabilizers, aircraft
Tanks, fuel: aircraft
Target drones
Targets, trailer type: aircraft
Tow targets
Training aids, aircraft: except electronic
Transmissions, aircraft
Turret test fixtures, aircraft
Turrets and turret drives, aircraft
Wheels, aircraft
Wing assemblies and parts, aircraft
Aircraft parts and auxiliary equipment are produced by 685 plants,
averaging 149 workers each. Most of these plants (55 percent)
employ less than 20 workers. Additional production data are shown
in Table 3-139. The raw materials and products are shown in
Figure 3-289. Aluminum, aluminum alloy, steel (stainless, alloy
and carbon), titanium, copper, brass, titanium alloy, copper
alloy, and nickel alloy are the major raw materials and are used
in the form of sheet, bar, plate and other various shapes. In
addition, coatings, adhesives, paints and solvents are used. The
principal manufacturing operations are mechanical material removal,
material forming, material coating, physical property modification,
3-740
-------
DRAFT
assembly and plastics molding. Because of the diversity of products
in this industry, no single description of a manufacturing operation
covers the whole field. In general, products are made from many
piece parts. These parts are machined, stamped or formed in metal
and plastic stock. The pieces are then cleaned, tested, subassembled
and cleaned again. The subassemblies are finally joined to form the
finished product which is usually tested. Process water is used
mainly for cooling during machining and rinsing. The rinsing oper-
ation is associated with chemical milling, conversion coating, heat
treating, plating and washing of lubricants chemicals, salts, etc.
following these operations.
The manufacture of aluminum propeller blades and wing skin sheets
is representative of the aircraft parts and auxiliary equipment
industry. A typical operation for manufacture of aluminum propellers
is shown in Figure 3-290. Aluminum propeller blanks are cast and
then machined to size and shape. A water-oil emulsion is used when
drilling and boring the butt end of the propeller. The butt is then
milled and following this, the chamber and the face are milled using
a water-oil emulsion. The blade portion is rough ground (dry)
during which the blade is bent twisted and aligned as required. It
is then finish ground and balanced. Following this the blade is
shot peened, reground and rebent retwisted and realigned if necessary.
It is then anodized, washed and rinsed before being initially inspected
After this initial inspection, the anodizing is stripped and the blade
is again washed and rinsed. Finish machining is done by boring the
inside and turning the outside of the butt-end using water-oil
emulsions for a coolant/lubricant. The blade is then shot peened
inside and outside, and the curve in the butt end is cold rolled. The
fairing is added next by putting a mold around the butt end of the
blade, pouring a lockfoam into the mold, curing it in an oven, sanding
it by hand when cured, and putting a sealed rubber sheet over it.
A heater is next bonded to the blade and the blade is anodized
again. Warning strips are painted on in spray booths utilizing
water curtains. The last step is a final inspection and balancing.
Another item typical of this industry is the manufacture of wing
skin (Figure 3-291) from metal sheet stock. The stock is first
inspected then sheared, stamped, milled (using water oil emulsions)
and bent to shape. The sheet is next aged by heat treating, then
alkali cleaned and rinsed. Following the rinse the metal is bright
dipped. This is to detect flaws and helps prepare the skin for
conversion coating. Between each dip, the metal is cleaned and air
dried. Then chemical milling is performed and the piece is rinsed,
followed by dipping and another rinsing. The skin is then inspected,
stripped, milled, ground, degreased, and inspected again. The skin
is degreased a last time then cleaned dipped and rinsed twice.
Finally, a conversion coat is applied and the piece is rinsed, assemble
and inspected.
-7 A 1
-------
DRAFT
PRODUCTION DATA Aircraft equipment, nee
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 307
WITH LESS THAN 20 EMPLOYEES 378
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 102,300
VALUE ADDED BY MANUFACTURE $2024.3 MILLION
VALUE OF SHIPMENTS $3036.6 MILLION
i
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 27
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 55
4 PHYSICAL PROPERTY MODIFICATION 82
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 82
7 MATERIAL COATING 73
*
8 ORE PROCESSING & REFINING Q
9 MOLDING & FORMING-NON-METALS 27
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
MA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE MA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-139
3-742
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DRAFT
Ship Building and Repairing
This industry includes establishments primarily engaged in build-
ing and repairing all types of ships, barges, and lighters,
whether propelled by sail or motor power or towed by other craft.
This industry also includes the conversion and alteration of
ships. Products in this SIC include:
Barges, building and repairing
Cargo vessels, building and repairing
Combat ships, building and repairing
Dredges, building and repairing
Drilling platforms, floating
Drydocks, floating
Ferryboats, building and repairing
Fireboats, building and repairing
Fishing vessels, large: seiners and trawlers-
building and repairing
Hydrofoil vessels
Landing ships, building and repairing
Lighters, marine: building and repairing
Lighthouse tenders, building and repairing
Marine rigging
Naval ships, building and repairing
Passenger-cargo vessels, building and repairing
Radar towers, floating
Sailing vessels, commercial: building and repairing
Scows, building and repairing
Ship building and repairing
Submarine tenders, building and repairing
Tankers (large craft), building and repairing
Tenders: large craft building and repairing
Towboats, building and repairing
Transport vessels, passenger and troop: building
and repairing
Tugboats, building and repairing
Yachts, building and repairing
Establishments primarily engaged in fabricating structural assemblies
or components for ships, or subcontractors engaged in ship painting,
joinery, carpentry work, electrical wiring installation, etc. are
classified in other industries.
Shipbuilding and repairing is done at 449 plants averaging 322 .
workers each. Many of these plants (61 percent) employ more than
20 workers. Additional production data are shown in Table 3-140.
As shown in Figure 3-292, 38 percent of the ships constructed are
3-746
-------
CRAFT
non-propeller type (e.g. barges, dredges, floats). Sixty-two per-
cent of the ships constructed are self propelled ships (e.g. yachts,
passenger ships, tankers, cargo ships, commercial sailing vessels).
Steel, aluminum, copper, wood and resins are the major raw materials.
A wide range of manufacturing processes are used in the shipbuilding
industry because of the differing raw materials and magnitude of
the products. These include material forming, mechanical material
removal, assembly operations, chemical processing, and material
coating.
In general, ship hulls are made by cutting and forming metal plates
and assembling then into large sections. These sections are then
jojned into the main hull structure. When the hull is unified, it,
is launched ard the super-structure and internal systems are com-
pleted. Process water which constitutes 8 percent of the gross
water used by the industry is used mainly for rinsing and cleaning
of the construction area. This rinsing is primarily for preparation
of the structure for painting.
r?he manufacture of large steel commercial ships is representative
of the shipbuilding industry. A typical operation for construction
of ship?; •'s shown in Figure 3-293. The sections of the hull are
formed iron plate steel. The section shapes are often cut from
templates by a flame torch. Bending and shaping of these pieces
is then performed with bends often kept in one direction to simplify
rolling and shaping operations. Welding of hull pieces is the
dominant form of joining. While these subassemblies are being con-
structed and joined in shops or outside (maximum size and weight
are determined by limitations such as available hoist equipment,
etc.), the keel of the ship is laid in the dock area. The hull
assemblies are then laid around this keel and structural members
are formed. Often, as the ship begins to increase in size, scaffold-
ing must be formed around the keel. As the hull is completed, in-
ternal structural members are added along with rudimentary assemblies
such as boiler casings and propeller bossing. This prepares the ship
for launching. Painting operations of the hull are done before
launching (i.e. cleaning hull, abrasive blasting, washing metal as
well as actual painting). A ship may be stern launched, side launch-
ed or drydock flooded depending on the design and available space
and equipment. After launching, the ship's superstructure and in-
ternal systems are completed. Again, all the basic metal forming
techniques are used in constructing the superstructure. At this
time duct work, wiring and other operational systems are added and
completed. Painting and/or panneling of interior sections is done
as one of the finishing procedures. Finally the interior is completed
and the ship is inspected and tested.
-------
DRAFT
PRODUCTION DATA Ship Building and Repairing
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 275
WITH LESS THAN 20 EMPLOYEES 174
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 144,600
VALUE ADDED BY MANUFACTURE $ 1880 MILLION
VALUE OF SHIPMENTS $3278.9 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING ft MOLDING - METALS 25
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 75
4 PHYSICAL PROPERTY MODIFICATION 25
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 0
7 MATERIAL COATING 100
*
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE 21.6 BILLION GALLONS
81.7 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 88
REUSED WATER AS PERCENT OF GROSS USE 12
PERCENT OF ESTABLISHMENTS REUSING WATER 40
PROCESS WATER AS PERCENT OF GROSS USE 8
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 85
PERCENT OF DISCHARGED WATER TREATED 1
NA NOT AVAILABLE *Based on Plant Data Collected
TABLE 3-140
3-748
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DRAFT
Boat Building and Repairing
This segment includes establishments primarily engaged in building and
repairing all types of boats. Products include:
Boat kits, wooden (not a model)
Boats, fiber glass: building and repairing
Boats: motorboats, sailboats, rowboats, and
canoes - building and repairing
Boats, rigid: plastic
Canoes, building and repairing
Dinghies, building and repairing
Dories, building and repairing
Fishing boats, small: such as lobster boats,
crab boats, and oyster boats
Houseboats, building and repairing
Hydrofoil boats
Kayaks, building and repairing
Life rafts, except inflatable (rubber and plastic)
Lifeboats, building and repairing
Motorboats, inboard and outboard: building and
repairing
Pontoons, except aircraft and inflatable
(rubber and plastic)
Skiffs, building and repairing
Tenders (small motor craft), building and
repairing
Boat building and repairing is done at 1755 plants, averaging 23
workers each. Most of these plants (79 percent) employ less than
20 workers. Additional production data are shown in Table 3-141.
As shown in Figure 3-294, 54 percent of the boats produced are out-
board motor boats, 3.5 percent are inboard outdrive boats and 35.7
percent are other boats such as sailboats, rowboats, and canoes.
Resins, wood, aluminum, steel and copper are the major raw materials.
The principal manufacturing operations are material forming and
assembly operations. However, a wide range of other manufacturing
processes are used in the boat building and repairing industry.
This is so mainly because of the differing raw materials which are
shown in Figure 3-295 and the different products in this industry.
-------
DRAFT
In the fiberglass boat industry the hull is formed in a hollow mold
and the frame attached. Purchased/ machined accessories are sub-
assembled and then the entire unit is assembled. In the aluminum
boat industry sheet aluminum is cut and formed and then assembled
primarily by riveting and bonding. The formed parts are usually
cleaned with caustic before final assembly. Very little process
water is used in the boat building industry. For fiberglass boats,
water is primarily used to hose down the final product. For
aluminum boats, a degreasing agent may be used for cleaning before
assembly of the sections.
Because of the diversity of products and materials used in the boat
building and repairing industry, no single product can be considered
typical. However, the manufacture of fiberglass boats (Reference
Figure 3-295) is a good example of the manufacturing processes in
this industry. A resin is sprayed into a hollow mold and a
fiber matt is layed in the resin. This is rolled and matted and
this whole process repeated several times to obtain the required
thickness. After the hull is built up to sufficient thickness,
the framework, which is usually built up from extruded aluminum
tubing, is laid and attached to the hull. Machined accessories
are usually purchased and for the most part consists of extruded
aluminum that is anodized for corrosion protection. These
accessories include trimwork, framing for windshields, and symbols.
Also parts such as seat assemblies and steering gear are .often pur-
chased. These parts are subassembled wherever possible before
attachment to the hull and frame network. As an example, the
plexiglass windscreen is attached to its supporting frame before
the frame and window subassembly is attached to the hull. Finally
the boat is inspected and tested.
3-752
-------
DRAFT
PRODUCTION iJ/'T X "J^st Buildin.j ^-',d Se
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Railroad Equipment
This segment includes establishments primarily engaged in building
and rebuilding locomotives (including frames and parts, not else-
where classified) of any type or gage; and railroad, street, and
rapid transit cars and car equipment for operation on rails for
freight and passenger service. This industry also includes
establishments primarily engaged in manufacturing trackless
trolley buses. Products in this category include:
Brakes, railway: air and vacuum
Cars and'car equipment, freight or passenger
Dining cars and car equipment
Engines, steam (locomotives)
Freight cars and car equipment
Heating units, for railroad cars
Industrial locomotives and parts, electric or
nonelectric
Interurban cars and car equipment
Locomotives, locomotive frames and parts
Lubrication systems, locomotive
Mining locomotives and parts, electric or
nonelectric
Railway maintenance cars
Railway motor cars
Rapid transit cars and equipment
Sleeping cars, railroad
Street cars and car equipment
Switching locomotives and parts, electric
and nonelectric
Tank freight cars and car equipment
Tenders, locomotive
Trolley bus poles
Trolley buses, trackless
Trolley retrievers
Trolley shoes
Railroad equipment is produced by 158 plants, averaging 318 work-
ers each. Many of these plants (63 percent) employ more than 20
workers. Additional production data are shown in Table 3-142.
3-756
-------
DRAFT
As shown in Figure 3-296, the manufacture and rebuilding of freight
cars are the major products of the market with steel, copper and
aluminum being the major raw materials. The principal manufacturing
operations are mechanical material removal, material forming,
chemical processing, material coating and assembly operations.
A wide range of diverse manufacturing processes are used in the
Railroad Equipment Industry. This is so mainly because of the
wide range of products and the complexity of these products. In
general, a railroad car is made by parallel manufacture of diverse
parts and subsequent fabrication of these parts into subassemblies
such as wheel assemblies and coach assemblies and eventually assembly
of the car to the frame. The construction of the body contains many
operations, such as sheet metal forming, application of insulation
and electrical wiring. Aluminum parts are normally anodized for
protection and steel parts are painted as part of the final oper-
ations. Most of the water used by the industry is used for plating
or cleaning operations. Many of these operations recycle the water
and do not discharge to treatment facilities except on rare
occasions. Water/oil emulsions used in cooling operations for
machining processes are often filtered and recycled through a
central reservoir unit which reclaims reusable solids from the
fluid.
The manufacture of Locomotives (Figure 3-297) is representative of
the Railroad Equipment industry because of the many processes in-
volved. A locomotive is assembled from several basic building
blocks which include undercarriage, fuel tank, traction motor, wheel
assemblies, cab assembly, diesel engine, D.C. generator, hood
section assembly, and control assemblies. Each of these assemblies
is constructed in parallel prior to the final assembly process.
Many parts and operations are involved in the construction of each
of these. For example, the motor and generator housings are cast
or formed and then machined. Many interior parts are cut, stamped and
then partially or completely plated before assembly. Armatures
are formed and assembled. The hood assembly starts from sheet or
plate steel. Its sections are cut, stamped and rolled into the
desired shapes before assembly by welding or riveting. The under-
carriage is formed from heavy plate and girder steel with the parts be:
cut, welded and primed with a protective undercoat before being sent t(
final assembly. The diesel engine itself is a maze of complex parts
fabricated by various processes. The block assembly is cut from heavy
gage steel then formed and machined where necessary to interface
with precision components. Pistons, crankshafts, cylinder walls
and the flywheel assembly along with many small components such as
valve assemblies are cut and undergo diverse machining processes before
ready for assembly to the engine. Once the engine itself is
complete, it is tested. The wheel assembly is cut, forged, ground and
finish machined before welding the assembly. The fuel tank is cut,
formed, welded and painted from sheet and bar stock. The control
3-757
-------
panel for the cab is cut, formed, welded and painted. When all of the
major locomotive subassemblies are complete, the final assembly begins.
The subassemblies and purchase parts are assembled by welding, brazing,
mechanical fasteners or adhesion bonding. After assembly the locomotive
is inspected and tested.
3-758
-------
DRAFT
i'-POUUCTIOK !">'•"
MJMBL-FGF F STALiL.'rHMENT^, WITH MORE THAN I' EMPLOYEES 95
vv!TH _LSS THAN 20 EMPLOYEES 59
;-:,".•=.-= her ' v,L ..L>,EE£ ALL ESTABLC-HV.' NTI fo.ioo
-'..'.i ' JDF'D lir MANUKACTUhL $]ji:.3 MILLION
vAL'JT r-F SH1TK-LNTS f 2 .: ; ;• i. Ml! LION
FrLCCr,NTOF ESTABLISHMENT? USING V.;-MUUC MANUFACTURING OPERATIONS,
1 CASTING 8t MOLDING - METAL?
2 MECHANICAL MATERIAL REMOVAL
3 MATERIAL FORMING - METALS
'' PHYSICAL PROPERTY MODIFICATION
5 ASSEMBLY OPERATIONS
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 25
7 MATERIAL COATING 75
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS Q
75 \
25
100 ,
WATER USE
ANNUAL GROSS WATER USE KA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
NA NOT AVAILABLE
*Baseci on Plant Data Collected
TABLE 3-142
3-759
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Motorcycles, Bicycles, and Parts
This segment includes establishments primarily engaged in manufacturing
motorcycles, bicycles, and similar equipment and parts. Establish-
ments primarily engaged in assembling motorcycles or bicycles from
purchased parts are also included in this industry. Products in
this industry are:
Bicycles and parts
Brakes, bicycle: friction clutch and other
Frames, motorcycle and bicycle
Gears, motorcycle and bicycle
Handle bars, motorcycle and bicycle
Motor scooters and parts
Motorbikes and parts
Motorcycles and parts
Saddles, motorcycle and bicycle
Seat posts, motorcycle and bicycle
Motorcycles,
averaging 80
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3-143. As sh
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2 percent of
are the major
are casting e
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bicycles and associated parts are produced by 219 plants,
workers each. Most of these plants (79 percent) employ
workers. Additional production data are shown in Table
own -Jr. rirure 3-298, 98 percent of the products pro-
industry are bicycles or bicycle products, while only
the product line is motorcycles. Steel and aluminum
raw materials. The principal manufacturing operations
nd molding, mechanical material removal, material coat-
fcrr.inc, and assembly operations.
In general motorcycles ard i::'cycles are made by bending, welding and
brazing tubing to forir. the frame. The frame is then painted (fre-
quently usinu electrostatic methods) before assembling wheels, handle-
bars, fenders, and the crank set. Process water is used mainly for
rinsing following come cf the machining, forming ar.d plating oper-
ations and fcr water curtails when spray painting.
The manufacture of bicycles (Figure 3-299) is representative of the
motorcycle and bicycle industry. bicycles consist of three main
sections: the- fr&:t;r? which includes the handlebars, forks, and kick-
stand, the wheels including the hub assemblies, and the crank set
including the sprockets and chain. Lightweight frames are fabricated
by rolling', forming, and seam welding or extruding low-carbon steel or
aluminum material. This tubing is then we-lded into connectors which
have been formed by casting and press forming raw material.
3-762
-------
DRAFT
The use of aluminum tubing and aluminum and alloy steel forgings
for major components contributes significant weight reductions.
An alternate method to welding to pre-formed connectors is brazing
with double butted tubing which has thicker walls at the ends
for added strength. The handlebars are made of either formed
aluminum tubing which is polished and buffed or chromium plated
steel tubing.
Front forks are made of seamless tubing that is cut to length,
plugged and swaged. Tube sections are then brazed into the fork
crown. Wheel rims are fabricated on a profile mill. In this
fabrication process, coil stock is formed, resistance seamed and
flash welded, polished, punched to accept spoke nipples, and
chromium plated. For lighter weight, polished aluminum alloy
rims are used. Spokes are cold drawn steel wire, that is treaded,
nickel-plated and are assembled to the rim by threaded brass nipples.
The hub assemblies are usually made of aluminum alloy castings, that
are ground and the axles and hub bearings are made of hardened steel
that is stamped, turned, ground and heat treated. The one piece crank
is a machined steel forging that is usually chromium plated for appearan
Sprokets are stamped from cold rolled steel strip, coined and chromium
plated.
Before assembly of the major components, the frame assembly under-
goes a painting process. Due to the complex shapes of the frame,
an electrostatic painting process is usually favored followed by
a baking procedure. The major assembly operations that follow
are done by hand. The crank set is mounted on the frame to which
is also added the brake systems and wheel assemblies. Trim such
as fenders and the chain guard are mounted next. Items such as
seats and handlebars are generally not mounted to facilitate
shipment.
3-763
-------
DRAFT
PRODUCTION DATA Motorcycles, bicycles, and parts
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 51
WITH LESS THAN 20 EMPLOYEES 168
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 17,600
VALUE ADDED BY MANUFACTURE $306.7 MILLION
VALUE OF SHIPMENTS $658.7 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTINGS MOLDING-METALS 0
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 100
4 PHYSICAL PROPERTY MODIFICATION 100
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 100
7 MATERIAL COATING 0
8 ORE PROCESSINGS REFINING 0
9 MOLDING & FORMING - NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-143
3-764
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DRAFT
Guided Missiles and Space Vehicles
This segment includes establishments primarily engaged in manufacturing
complete guided missiles and space vehicles. Research and develop-
ment and other services on or for guided missiles and space vehicles
are included in this industry. Products in this industry include:
Ballistic missiles, complete
Guided missiles, complete
Research and development of guided missiles
and space vehicles
Rockets (guided missiles), space and military:
complete
Space vehicles, complete
Establishments primarily engaged in manufacturing guided missile
and space vehicle propulsion units and propulsion unit parts are
classified in Industry 3764; space satellite, and guided missile
and space vehicle airborne and ground guidance, checkout and launch
electronic systems and components in Industry 3662; and guided
missile and space vehicle airframes, nose cones, and space cap-
sules in Industry 3769.
Guided missiles and space vehicles are produced by 71 plants,
averaging 1725 workers each. Most of these plants (82 percent)
employ more than 20 workers. Additional production data are shown
i.n Table 3-144, The raw materials and products are shown in Figure
3-300. Aluminum, aluminum alloy, steel (stainless, alloy, and
carbon), titanium, titanium alloy, copper, copper alloy, and nickel
alloy are used in the form of sheet, bar, plate and other various
shapes. In addition, various coatings are also used. The principal
manufacturing operations are mechanical material removal, chemical/
electrochemical operations, physical property modification, material
forming (metal), assembly operations, material molding and forming
(plastics).
Guided missiles and space vehicles are built by manufacturing and
assembling various components into subassemblies. The missile is
finished by assembling the various major subassemblies making up
the engine, main structure, guidance control and payload. Process
water is used mainly for rinsing and cooling. The rinsing oper-
ation is associated with chemical milling, anodizing, conversion
coatings, heat treating, plating and the washing of the lubricants,
chemicals and salts, etc. following these operations.
The manufacture of guided missiles is representative of the guided
missile and space vehicle industry. A typical operation for making
guided missiles is shown in Figure 3-301. The outer housing case is
3-767
-------
made by shearing sheet stock and rolling (using a forming lubricant)
the stock into a cylindrical shape that is seam welded. The upper
dome is formed by casting the basic shape then milling and grinding
it to its finished form. After this, a hole is drilled and thread-
ed (using soluble oil and cutting oil, respectively) in the center
of the dome, for assembly of the igniter. The nozzle assembly is
made by casting the basic form then milling and grinding the casting
into its finished shape. The final assembly is then started by
welding the upper dome to the case and then placing a rod down the
center of the case. Next, the propellant is poured into the case,
the rod is removed and the nozzle assembly is welded into place at
the other end of the case. Then the ignitor is threaded into the
hole in the dome. Several engines (number depending on how many
stages) are bolted to one another using explosive bolts, and the
guidance control is bolted to the top engine also using explosive
bolts. The guidance control contain all the instrumentation,
altitude control, self-destruct assemblies, etc. The warhead (or
other payload) is then bolted to the guidance control unit.
3-768
-------
DRAFT
PRODUCTION DATA Guided missiles and space vehicles
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES -8
WITH LESS THAN 20 EMPLOYEES 13
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 122,500
VALUE ADDED BY MANUFACTURE $3127.2 MILLION
VALUE OF SHIPMENTS $4326.4 MILLION ^
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS
2 MECHANICAL MATERIAL REMOVAL
3 MATERIAL FORMING - METALS
4 PHYSICAL PROPERTY MODIFICATION
5 ASSEMBLY OPERATIONS
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS
7 MATERIAL COATING 100
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 0
0
100
100
100
100
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-144
3-768A/J-768B
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DRAFT
Guided Missile and Space Vehicle Propulsion
Units and Propulsion Unit Parts
This segment includes establishments primarily engaged in manufactur
guided missile propulsion units and propulsion unit parts. Research
and development on guided missile and space vehicle propulsion units
and propulsion unit parts is also included in this industry. Produc
in this industry include:
Engines and engine parts, guided missile
Research and development of guided missile and
space vehicle engines
Propulsion units for guided missiles and space
vehicles
Rocket motors, guided missile
Guided missile and space propulsion units and parts are produced
by 29 plants, averaging 714 workers each. Most of these plants
(96 percent) employ more than 20 workers. Additional production
data are shown in Table 3-145. Figure 3-302 shows the materials
used which include aluminum, aluminum alloy, steel (stainless,
alloy, carbon), titanium, titanium alloy, copper, copper alloy and
nickel alloy. In addition various coatings are also used. The
principal manufacturing operations are casting and molding (metal),
material forming, mechanical material removal, material coating,
and assembly operations.
Propulsion units are made by manufacturing the discrete component
parts and assembling them. Inspection and testing complete the
finished propulsion unit. Process water, which constitutes 11 per-
cent of the gross water used by the industry, is used mainly for
rinsing following both machining operations and any required plating
operations.
A typical operation for manufacture of a monopropellant hydrazine
altitude control engine is shown in Figure 3-304. First, the reactic
chamber is machined from bar stock, as shown in Figure 3-303, finish*
parts manufacture. It is then cleaned and injection tubes are bondec
(with an adhesive) to the chamber. Diffusion screens, covering the
openings to the injection tubes, are spot welded to the chamber. A
flow and pressure check is then run on the assembly and the assembly
is half filled with a catalyst. Another diffusion screen is pressed
against the catalyst inside the chamber and then spotwelded in
place. Next, the chamber is completely filled with catalyst. Anothe
diffusion screen is pressed against this, spotwelded in place and th«
nozzle is welded to the reaction chamber. Following this, the manifc
is brazed to the injection tubes and a thermal standoff is brazed to
the reaction chamber. The manifold is then brazed to the thermal stc
off and the unit is inspected and then cleaned. After cleaning, the
propellant valve is brazed to the manifold completing the assembly.
-------
DRAFT
PRODUCTION DATA Space propulsion units and parts
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 28
WITH LESS THAN 20 EMPLOYEES 1
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 20,700
VALUE ADDED BY MANUFACTURE $506.7 MILLION
VALUE OF SHIPMENTS $716.3 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING — METALS 0
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 66
4 PHYSICAL PROPERTY MODIFICATION 66
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 1QO
7 MATERIAL COATING 66
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 0
WATER USE
ANNUAL. GROSS WATER USE 42.1
159.3
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
27
73
79
11
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 24
PERCENT OF DISCHARGED WATER TREATED 9
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-145
3-772
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DRAFT
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DRAFT
Guided Missile and Space Vehicle Parts and
Auxiliary Equipment, Not Elsewhere Classified
This segment includes establishments primarily engaged in manufacturing
guided missile and space vehicle parts and auxiliary equipment, not
elsewhere classified. Research and development on guided missile
and space vehicle parts and auxiliary equipment, not elsewhere
classified, is also included in this industry. The major products
include:
Airframe assemblies, for guided missiles
Bellows assemblies for missiles, metal
Casings for missiles and missile components,
shipping and storage
Nose cones, guided missile
Research and development of guided missile and
space vehicle components
Space capsules
Guided missiles and space vehicle parts and auxiliary equipment
are produced by 44 plants, averaging 461 workers each. Most of
these plants (82 percent) employ more than 20 workers. Additional
production data are shown in Table 3-146. The raw materials and
products are shown in Figure 3-305, and include sheet, bar, plate
and other various shapes of aluminum, aluminum alloy, steel (stain-
less, carbon, and alloy), titanium, titanium alloy, copper,* copper
alloy and nickel alloy. In addition various coatings are also used.
The principal manufacturing operations are casting and molding
(metals), material forming (metals), material coating, assembly
operations, mechanical material removal, molding and forming (non-
metals) .
Because of the diversity of products in this industry, no single
description of a particular product covers the whole field. In
general, products are made from many piece parts. These parts are
machined, stamped or formed in metal and plastic stock. The parts
are then cleaned, tested, subassembled and cleaned again. The
subassemblies are finally joined to form the finished product which
is then tested. Process water, which constitutes 11 percent of the
gross water used by the industry, is used mainly for cooling and
rinsing. The rinsing operation is associated with chemical milling,
conversion'coating, heat treating, plating, and washing of lubricants,
chemicals, salts, etc. following these operations.
.3-776
-------
The manufacture of metal cast components and the manufacture and
assembly of nose cones are representative of the guided missile
and space vehicle parts and auxiliary equipment industry. A typical
operation for manufacturing metal cast components is shown in Figure
3-306 while Figure 3-307 shows the manufacture and assembly of nose cone
The manufacture of metal cast components is initiated by casting the
I desired shape and then milling, turning, drilling or boring the
casting using water-soluble oil. The parts are then cleaned, ground,
honed and cleaned again. Finally, they are painted and then assembled
with other components to form subassemblies and assemblies.
The manufacture and assembly of nose cones (Figure 3-307) is initiated
with the fabrication of the frame. This is done by first shearing,
blanking, rolling, and bending sheet stock, sometimes using a form-
ing oil. The frame parts are then cleaned and heat treated. Bend-
ing and heat treating may be repeated to achieve the final shape.
Cutting the frame pieces to size and removing the burrs follows,
after which the pieces are anodized, riveted together (assembly),
and painted. A tungsten nose piece is formed and bolted to the front
of the frame and then the skin is applied. The skin is sheet metal that
is sheared and bent, using a forming oil, and then assembled to the
frame by riveting. An asbestos phenolic cloth is wrapped around
the skin and coated several times with a resin. Finally, the in-
struments, etc. are attached inside the nose cone, and it is inspected
and tested.
3-777
-------
DRAFT
PRODUCTION DATA Space vehicle equipment, nee
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 36
WITH LESS THAN 20 EMPLOYEES 8
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 20,300
VALUE ADDED BY MANUFACTURE $507.1 MILLION
VALUE OF SHIPMENTS $775.7 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING — METALS ' 0
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 100
4 PHYSICAL PROPERTY MODIFICATION j_oO
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS IQQ
1 MATERIAL COATING 100
8 ORE PROCESSING & REFINING 0
9 MOLDING a FORMING — NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE 42.1 BILLION GALLONS
159.3 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 27
REUSED WATER AS PERCENT OF GROSS USE 73
PERCENT OF ESTABLISHMENTS REUSING WATER 79
PROCESS WATER AS PERCENT OF GROSS USE 11
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 24
PERCENT OF DISCHARGED WATER TREATED NA
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NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-146
3-778
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DRAFT
Travel Trailers and Campers
This segment includes establishments primarily engaged in manufacturing
travel trailers for attachment to passenger cars or other vehicles,
pickup coaches (campers) or caps (covers) for mounting on pickup
trucks and self-contained motor homes. Travel trailers are gen-
erally 35 feet long or less, 8 feet wide or less, and have storage
facilities for water and waste. Specific products include:
Campers, for mounting on trucks
Automobile house trailer chassis
Camping trailers and chassis
Chassis for camping trailers
House trailers except as permanent dwellings
Motor homes, self-contained
Pickup coaches (campers), for mounting on pickup
trucks
Pickup covers, canopies or caps
Tent-type camping trailers
Trailer coaches, automobile
Trailers, house: except as permanent dwellings
Truck campers (slide-in campers)
Travel Trailers and Campers are produced by 1013 plants, averaging
34 workers each. Most of these plants (66 percent) employ less than
20 workers. Additional production data are shown in Table 3-147.
As shown in Figure 3-308, 49 percent of the units produced are the
recreational type while 51 percent are camping trailers, campers or
pick-up covers (Kaps). Steel, aluminum, wood, copper, fiberglass,
plastics and fabrics are the major raw materials. The principal
manufacturing operations are material forming, assembly operations,
and material coating.
In general travel trailers and campers are made by assembly of ex-
truded and stamped parts on a welded chassis framework. The floor-
ing is often wood and most of the permanent accessories (e.g. sinks,
lavatory facilities, stoves) are directly fastened to the flooring
before the enclosing structure is formed. Based on data obtained
during this survey 92% of the plants contacted had no point source
discharge. This is primarily due to the fact that most plants in
this industry segment do not use any process water.
The manufacture of Travel Trailers is representative of the Travel
Trailer and Camper Industry. A typical operation for making Travel
Trailers is shown in Figure 3-309. Generally, the trailers frames are
-------
DRAFT
cut, formed and assembled. Mounting brackets are assembled to the
frame. The flooring is usually cut and finished from wood and
assembled to the frame.
Either vacuum formed plastic or formed metal wheel wells are attached
to this floor section before the flooring is attached to the frame
assembly. The entire assembly then receives a protective under-
coat. Next the interior flooring is added (either carpeting or a ti]
and the cabinetry and permanent interior fixtures are added (e. g.
sinks, lavatories). The cabinets are pre-assembled and finished
before installation and are typically made of wood. The sink and
lavatory facilities are either formed of plastic or fiberglass.
While this floor assembly is being unitized, the shell of the trailer
which is typically made of stamped sheets and extruded aluminum
framework, is being formed and pre-assembled in sections ready for
installation around the finished interior. Sometimes a foam insul-
ation is sprayed on the outer shell and sandwiched between the metal
exterior and wooden interior for thermal and acoustical insulation.
The metal exterior is typically finished before assembly to the
chassis so the final finish operation is assembly of extruded trim
work and window and door attachment. Pre-assembled upholstery is
then added and everything is assembled to the frame. The unit
undergoes operational inspection to test out any auxiliary power unit
that may have been incorporated.
-------
DRAFT
PRODUCTION DATA Travel trailers and campers
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 366
WITH LESS THAN 20 EMPLOYEES 647
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 34,500
VALUE ADDED BY MANUFACTURE $ 449 MILLION
VALUE OF SHIPMENTS $1213.2 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTINGS MOLDING-METALS 0
2 MECHANICAL MATERIAL REMOVAL 17
3 MATERIAL FORMING — METALS 34
4 PHYSICAL PROPERTY MODIFICATION 17
5 ASSEMBLY OPERATIONS 83
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 0
7 MATERIAL COATING 34
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING — NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
MA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-147
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Tanks and Tank Components
This segment includes establishments primarily engaged in manufacturim
or assembling complete tanks, and specialized components for tanks.
Specific products are:
Amphibian tanks, military
Tank components, specialized: mili-
tary
Tank recovery vehicles
Tanks, military: including factory re-
building
Tank and tank components are produced by 22 plants, averaging 268
workers each. Most of these plants (68 percent) employ more than 20
workers. At the present time only one facility is actually making a
final tank assembly. Additional production data are shown in Table
3-148. As shown in Figure 3-310, iron, steel, aluminum and copper
are the major raw materials consumed. The major manufacturing processe
are mechanical material removal, material forming, chemical/electro-
chemical processing, material coating and assembly operations.
A wide range of diverse manufacturing processes are used in the tank
industry. This is so mainly because of the differing raw materials
as shown in Figure 3-311 and the severe physical demands a tank must
be designed to meet. Armor steel for tanks varies with application.
In general, armor steel contains between 0.2 and 0.4 percent carbon.
Armor is generally heat treated to increase its hardness, then temp-
ered to make it tough and less brittle. Process water in this industry
is used in chemical processing (alodining and phosphate coating) and
in spray paint booths as a water curtain to catch overspray.
The manufacture of tanks (Figure 3-311) is representative of the tank
and tank component industry. The basic unit of the tank assembly is
the hull which is formed by casting. Machining operations are done
on this casting in the turret mounting area to accept the turret mount-
ing hardware. Welding is also done on the hull casting to add support
brackets for engine and wheel mounting. Following manufacture, the
hull is painted and then the suspension system is assembled to it.
The wheels, which consist of a rubber covered aluminum hub and idler
wheels (support wheels for upper portion of track), are mounted to the
suspension assembly. The final drive sprocket, which ties the
transmission to the track, is then added. Next, most of the interior
-------
DRAFT
control and communication systems are assembled onto the tank. The
tracks are then mounted. They are formed from steel plates which
are joined in a hinged fashion and have a removable rubber shoe for
traction, smooth ride and quietness. The engine is then mounted in-
to the hull along with the fuel tanks. The drive system is tested
before the turret is mounted.
The turret is a cast assembly that is machined and welded to mate with
the hull to accept accessories such as gun assemblies and ammo storage
racks. The turret is prime painted after machining and welding oper-
ations and the gun barrel is then mounted. The interior components of
the turret, such as communications and control wiring and ammo storage
racks, are then added. The turret platform, which is a floor assembly
that is connected to and rotates with the turret, is mounted under-
neath the turret. This platform is constructed from welded and formed
plate and bar stock. The pilot's cupola, which is a free rotating
turret located on the main turret, is then mounted. This piece is a
cast assembly and is similar in construction technique to the main
turret.
After the track fenders are mounted over the tracks and the unit
undergoes a complete operational test, the entire assembly receives
a final coat of paint and is covered with a tent like structure for
shipping.
3-788
-------
DRAFT
PRODUCTION DATA Tanks and tank components
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 15
WITH LESS THAN 20 EMPLOYEES 7
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 5 , 900
VALUE ADDED BY MANUFACTURE $111.7 MILLION
VALUE OF SHIPMENTS $272.2 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTINGS MOLDING-METALS
2 MECHANICAL MATERIAL REMOVAL
3 MATERIAL FORMING-METALS
4 PHYSICAL PROPERTY MODIFICATION
5 ASSEMBLY OPERATIONS
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 10°
7 MATERIAL COATING 10°
8 ORE PROCESSING & REFINING °
9 MOLDING & FORMING - NON-METALS °
0
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WATER USE
ANNUAL GROSS WATER USE
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BILLION GALLONS
BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-148
3-789
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DRAFT
Transportation Equipment, Not Elsewhere Classified
This segment includes establishments primarily engaged in manufacturing
transportation equipment, not elsewhere classified. Products include:
All terrain vehicles (ATV)
Automobile trailer chassis, except house
trailer
Autos, midget: power driven
Caddy cars
Chassis, automobile trailer: except house
trailer
Electrocars, for transporting golfers
Gocarts, except children's
Pushcarts
Snowmobiles
Trailers, except house and recreational: for
automobiles
Wheelbarrows
Transportation equipment is produced by 481 plants, averaging 36
workers each. Most of these plants (62 percent) employ less than
20 workers. Additional production data are shown in Table 3-149.
As shown in Figure 3-312, the majority of the products in this
category are trailers and carts. A smaller part of the market con-
sists of snowmobiles and golf carts. Steel, aluminum and .fiberglass
resin are the major raw materials. The principal manufacturing oper-
ations are cutting, mechanical material removal, material forming,
and assembly operations.
In general small transportation vehicles are made by welding steel
or aluminum sheet stock and structural members into basic frames.
Over this, plastic or fiberglass bodies are attached for appear-
ance or functions such as waterproofing for flotation. Suspension
systems for wheeled small vehicles generally depend on large soft
tires rather than mechanical spring assemblies. Often suspensions
are totally absent such as in go-carts. Transmissions and power
plants, whether electric as in a golf cart or gasoline such as an
all terrain vehicle (ATV), are manufactured in much the same way
as in larger vehicles such as automobiles. For gasoline engines,
cast blocks are machined to accept other parts such as crankshafts,
pistons, bearings and connecting rods. Usually 2 stroke engines
are used in this class of vehicle due to their operating character-
istics and versatility as well as their operational simplicity
In electric vehicles such as golf carts, d. c. motors are manufactured
-------
DRAFT
to be powered from portable supplies such as lead-acid batteries.
Cast-housings accept armature ^assemblies containing wound copper
wire, commutators, and brush assemblies as well as permanent mag-
nets (high torque at slow speed and high efficiency).
Little process water is used in this industry and what water is
employed is used primarily in the machining processes as a clean-
ing agent or coolant.
The manufacture of All Terrain Vehicles (ATV's) (Figure 3-313) is
representative of the Transportation Equipment Not Elsewhere Class-
ified Industry. The typical ATV is a six wheeled, soft tired,
amphibious vehicle with a plastic body and a two stroke engine.
The construction begins with the forming of the basic chassis weld-
ment. Angle iron and channel stock are cut, bent, formed, drilled,
slotted, and joined to form a rigid structure that will accept mount-
ing of all the drive components. The body is vacuum molded, usually
in two pieces (bottom and top sections). The bottom section is a
tub shape having holes to accept the mounting of the frame and the
protruding axle shafts. Where the axle penetrates the body,
gaskets, bushings, and sealed bearings are used to form a water
tight shell for flotation. The wheels and the drive assembly are
mounted next. The drive mechanism consists mainly of a two stroke
engine which is bolted to the frame, a torque converter and a chain
and sprocket drive system. All are mounted to prepared brackets on
the frame. With the internal assembly complete, the upper body
assembly, which is primarily vacuum molded plastic, is installed.
This assembly usually contains the cockpit for the passengers, a
vent system for the power plant, and the fuel tank. Painting may
be done on exposed metal such as the wheels, but the plastic body
does not need further protection.
3-793
-------
DRAFT
PRODUCTION DATA Transportation equipment, nee
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 181
WITH LESS THAN 20 EMPLOYEES 300
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 17,300
VALUE ADDED BY MANUFACTURE $248.1 MILLION
VALUE OF SHIPMENTS $705.8 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 0
2 MECHANICAL MATERIAL REMOVAL 50
3 MATERIAL FORMING - METALS IQO
4 PHYSICAL PROPERTY MODIFICATION 50
5 ASSEMBLY OPERATIONS 10o
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 50
7 MATERIAL COATING 100
8 ORE PROCESSING & REFINING 0
*
9 MOLDING & FORMING - NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
•'Based on Plant Data Collected
TABLE 3-149
3-794
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DRAFT
Engineering/ Laboratory/ Scientific/ and Research Instruments and
Associated Equipment
This segment includes establishments primarily engaged in manufacturing
engineering, laboratory, and scientific instruments, including nautical
navigational, aeronautical, surveying, and drafting equipment and in-
struments for laboratory work and scientific research. The major
products are:
Acceleration indicators and systems
components, aerospace type
Airspeed instrumentation (aeronautical
instruments)
Aircraft flight instruments
Alidades (surveying instruments)
Altimeters, standard and sensitive (aeronautical
instruments)
Angle-of-attack instrumentation
Angle-of-yaw instrumentation
Autoclaves, laboratory
Automatic pilots, aircraft
Bacteriological laboratory instruments: except
medical, optical, and dental
Balances, laboratory
Bank and turn indicators and components
(aeronautical instruments)
Binnacles (compass housings)
Blood testing apparatus
Bunsen burners
Calibration tapes, for physical testing machines
Calorimeters
Centrifuges, laboratory
Chemical laboratory apparatus
Clinical laboratory instruments, except medical
and dental
Coal testing apparatus
Compasses and accessories, except portable
(navigational instruments)
Degaussing equipment
Distilling apparatus, laboratory type
Drafting instruments and machines: T-squares,
templates, etc.
Driftmeters, aeronautical
Dust sampling and analysis equipment
3-797
-------
Environmental testing equipment
Fathometers
Furnaces, laboratory: except dental
Gas analyzing equipment
Generators, magnetic idealization
Glide slope indicators
Gyro gimbals
Gyrocompasses
Gyropilots
Gyroscopes
Haemoglobinometers
Horizon flight indicators
Hydrogen ion equipment, colorimetric
Incubators, laboratory
Integrators (mathematical instruments)
Laboratory equipment: fume hoods, distillation
racks, benches, cabinets
Laboratory testing and scientific instruments,
except electric
Laser beam alinement devices
Laser scientific and engineering instruments
Machmeters
Magnetic idealization generators
Map plotting instruments
Micromanipulator
Microtomes
Meteorological instruments: laboratory,
except optical
Nautical instruments
Navigational instruments
Omni-bearing indicators
Pellicle mirrors
Petroleum product analyzing apparatus
Photogrammetry equipment
Photopitometers
Physics laboratory apparatus and instruments
Pi tapes (metal periphery direct reading
diameter tapes)
Pictorial deviation indicators
Pipettes, hemocytometer
Pitometers
Plani'meters
Plotting instruments, drafting and map reading
Plumb bobs
Position indicators for landing gear, cowl
flaps, stabilizersr etc.
Pumps, vacuum: laboratory
Radio magnetic instrumentation (RMI)
Rate-of-climb instrumentation
3-798
-------
DRAFT
Seismographs
Seismometers
Seismoscopes
Sewage testing apparatus
Sextants
Shadowgraphs
Slide rules
Standards and calibrating equipment,
laboratory
Surveying instruments and accessories
Tables, work: laboratory
Taffrail logs
Theodolites (surveying equipment)
Time interval measuring equipment, electric
(laboratory type)
Time measuring and counting equipment,
electric (laboratory type)
Transits, surveyors'
Turntable indicator testers
Water testing apparatus
Engineering and scientific instruments are produced by 721 plants,
averaging 51 workers each. Most of these plants (65 percent) employ
less than 20 workers. Additional production data are shown in Table
3-150. As shown in Figure 3-314, 52 percent of the production is in
the area of aeronautical and navigational instruments, while 31 per-
cent is in the laboratory and scientific instrument category. The
remaining 17 percent consists of miscellaneous instruments. Raw
materials used include copper, aluminum, steel, electric motors,
vacuum tubes, bearings and semiconductors. The principal manufactur-
ing operations are mechanical material removal, material forming,
assembly operations and material coating.
A wide range of manufacturing processes are used in the scientific
instrument industry. This is so mainly because of the differing
raw materials, which are shown in Figure 3-315, and the variety of
products produced. Process water, which constitutes about 6.5
-------
percent of the gross water used by the industry, is used mainly for
surface treatment operations and cleaning. > . ,
The manufacture of an airborne integrated data system (AIDS) is
representative of the scientific instrument industry. As shown in
Figure 3-315, sheet metal stock is stamped, punched, drilled, bent
and formed to make various parts of the chassis. These parts are
then assembled by welding and after assembly, are usually surface
treated by anodizing or a similar process. Electrical components
are then installed in the completed chassis and wired to complete
the AIDS controller itself. To operate, electronic circuit cards
must be added to the chassis and inter-connections added to out-
side sensors and systems.
3-800
-------
DRAFT
Engineering, Laboratory, Scientific, and Research
PRODUCTION DATA Instruments and Associated Equipment
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 255
WITH LESS THAN 20 EMPLOYEES 466
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 36 , 700
VALUE ADDED BY MANUFACTURE $ 654.1 MILLION
VALUE OF SHIPMENTS $1018.6 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING -METALS 0
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 80
4 PHYSICAL PROPERTY MODIFICATION 20
5 ASSEMBLY OPERATIONS 80
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 0
7 MATERIAL COATING 40
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING-NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE 3.1
11.7
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
22.6
77.4
75
6.45
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 22.6
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
i TABLE 3-150
i 3-801
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UKAS- !
Automatic Controls for Regulating Residential and Commercial
Environments and Appliances
This segment includes establishments primarily engaged in manufacturing
temperature and related controls for heating and air-conditioning
installations and refrigeration applications, which are electrically,
electronically, or pneumatically actuated, and which measure and
control variables such as temperature and humidity; and automatic
regulators used as components of household applicances. The prin-
cipal products include:
Air flow controllers, air conditioning and
refrigeration: except valves
Appliance regulators, except switches
Building services monitoring controls, automatic
Clothes drier controls, including dryness controls
Combination limit and fan controls
Combination oil and hydronic controls
Damper operators: pneumatic, thermostatic,
electric
Electric air cleaner controls, automatic
Electric heat proportioning controls, modulating
controls
Electric space heater controls, automatic
Energy cutoff controls, residential ana commercial
types
Fan control, temperature responsive
Flame safety controls for furnaces and boilers
Float controls, residential and commercial types
Gas burner automatic controls, except valves
Gradual switches, pneumatic
Humidistats: wall, duct, and skeleton
Humidity controls, air conditioning types
Hydronic circulator control, automatic
Hydronic limit control
Hydronic pressure and temperature controls
Ice bank controls
Icemaker controls
Ignition controls for gas appliances and furnaces,
automatic
In-built thermostats, filled system, and bimetal
types
Incinerator control systems, residential and commercial
types
Limit controls, residential and commercial heating
types
3-804
-------
DRAFT
Line or limit control for electric heat
Liquid level controls, residential and
commercial heating types
Oven temperature controls, nonindustrial
Pneumatic relays, air-conditioning type
Pressure controllers, air-conditioning system
type
Primary oil burner controls, including stack
controls and cadmium cells
Refrigeration/air-conditioning defrost controls
Refrigeration controls (pressure)
Refrigeration thermostats
Sequencing controls for electric heat
Static pressure regulators
Steam pressure controls, residential and
commercial type
Surface burner controls, temperature
Switches, pneumatic positioning remote
Switches, thermostatic
Temperature controls, automatic: residential and
commercial types
Temperature sensors for motor windings
Thermocouples, vacuum: glass
Thermostats
Time program controls, air conditioning systems
Vapor heating controls
Water heater controls
Environmental Controls are produced by 129 plants, averaging 228
workers each. About half of these plants (47 percent) employ more
than 20 workers. Additional production data are shown in Table
3-151. On a dollar basis, about 50 percent of the environmental
controls are temperature responsive thermostats with the balance
being distributed among various other types of environmental controls
A diversity of raw materials is required, as can be seen from the
production data in Figure 3-316. A multiplicity of operations are
performed on these raw materials including mechanical material re-
moval, material forming, assembly operations, and material coating.
In general, environmental controls are made by forming mechanical
components in linkages to sense the desired environmental parameter
and produce a corresponding mechanical output. These are then
mounted in a case along with a dial, pointer and clear cover.
Process water, which constitutes 23 percent of the gross water used
-------
DRAF
by the industry, is used mainly for plating and cleaning operations
and ultrasonic machining.
The manufacture of thermostats is representative of the environmental
controls industry. Figure 3-317 describes this manufacture. Initially,
raw mill stock is stamped, shaped, formed, bent, etc. to the confi-
gurations required in the final thermostat. The bimetal strip is
fabricated by bonding two dissimilar metal strips together. The
bimetal strip is then drilled and riveted to a ceramic back plate,
and an electrical contact is staked onto the bimetallic strip.
Metallic parts (except bimetal strip) are usually finished by plating,
anodizing, or applying similar surface treatments. Other components
such as the dial cover lens are then assembled to form the final
thermostat.
3-806
-------
DRAFT
Automatic Controls for Regulating Residential and
PRODUCTION DATA commercial Environments and Appliances
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES go
WITH LESS THAN 20 EMPLOYEES 69
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 29 , 400
VALUE ADDED BY MANUFACTURE $526.6 MILLION
VALUE OF SHIPMENTS $754.5 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 25
2 MECHANICAL MATERIAL REMOVAL 75
3 MATERIAL FORMING - METALS 25
4 PHYSICAL PROPERTY MODIFICATION 50
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 75
7 MATERIAL COATING 100
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING-NON-METALS 0
WATER USE
ANNUALGROSS WATER USE 3.0 BILLION GALLONS
11.625 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE go
REUSED WATER AS PERCENT OF GROSS USE 40
PERCENT OF ESTABLISHMENTS REUSING WATER 60
PROCESS WATER AS PERCENT OF GROSS USE 23.33
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 56.67
PERCENT OF DISCHARGED WATER TREATED 17.65
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-151
3-807
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Industrial Instruments for Measurement, Display, and Control of
Process Variables; and Related Products
This segment includes establishments primarily engaged in manufacturing
industrial instruments and related products for measuring, displaying
(indicating and/or recording), transmitting, and controlling process
variables in manufacturing, energy conversion, and public service
utilities. These instruments operate mechanically, pneumatically,
electronically, or electrically to measure process variables such
as temperature, humidity, pressure, vacuum., combustion, flow, level,
viscosity, density, acidity, alkalinity, specific gravity, gas and
liquid concentration, sequence, time interval, mechanical motion,
and rotation. The major products include:
Absorption analyzers, industrial process
type: infra-red, X-ray, etc.
Analyzers, industrial process type
Annunciators, relay and solid state types:
industrial display
Boiler controls: industrial, power, and
marine type
Buoyancy instruments, industrial process
type
Chromatographs, industrial process type
Combustion control instruments, except
commercial and household furnace type
Computer interface equipment for industrial
process control
Controllers for process variables: electric,
electronic, and pneumatic
Coulometric analyzers, industrial process
type
Data loggers, industrial process type
Density and specific gravity instruments,
industrial process type
Differential pressure instruments, industrial
process type
Digital displays of process variables
Draft gauges, industrial process type
Electrodes used in industrial process measure-
. ment
Electrolytic conductivity instruments,
industrial process type
Flow instruments, industrial process type
3-810
-------
DRAFT
Fluidic devices, circuits, and systems for
process control
Gas and liquid analysis instruments,
industrial process type
Gas flow computers, industrial process type
Humidity instruments, industrial process
type
Hydrometers, industrial process type
Hygrometers, industrial process type
Industrial process control instruments
Infra-red instruments, industrial process
type
Level and bulk measuring instruments,
industrial process type
Liquid analysis instruments, industrial
process type
Liquid concentration instruments, in-
dustrial process type
Liquid level instruments, industrial
process type
Magnetic flow meters, industrial process
type
Manometers, industrial process type
Moisture meters, industrial process type
Nuclear reactor controls
Panelboard indicators, recorders and
controllers: receiver type
PH instruments, industrial process type
Potentiometric self-balancing instruments,
except X-Y plotters
Pressure gauges, dial and digital
Pressure instruments, industrial process
type
Primary elements for process flow measurement:
orifice pletes, etc.
Programmers, process type
Pyrometers, industrial process type
Refractometers, industrial process type
Resistance thermometers and bulbs, in-
dustrial process type
Telemetering instruments, industrial
process type
Temperature instruments: industrial
process *"/p;t:l. ":
-------
DM AI" 1
Thermometers, filled system: industrial
process type
Time cycle and program controllers,
industrial process type"
Transmitters of process variables,
standard signal conversion
Turbidity instruments, industrial process
type
Turbine flow meters, industrial process
type
Viscosimeters, industrial process type
Water quality monitoring and control
systems
Process control instruments are produced by 176 plants, averaging
196 workers each. Most of these plants (68 percent) employ more
than 20 workers. Additional production data are shown in Table
3-152. As shown in Figure 3-318, pressure control instruments are
by far the largest product area in this industry. Mill shapes and
forms, fractional H.P. motors and semiconductors are the major raw
materials. The principal manufacturing operations are mechanical
material removal, material forming, assembly operations and material
coating.
In general, process control instruments are made by fabricating the
various parts of the instrument such as the case, dial and. glass or
plastic face and then painting or coating the case and calibrating
the dial before assembling the parts into the final instrument.
Process water, which constitutes 33 percent of the gross water used
by the industry, is used mainly during plating, cooling and cleaning
operations.
Because of the diversity of products and materials used in the process
control instruments industry, no single product can be considered
typical. However, the manufacture of a temperature control instrument
(Figure 3-319) is a good example which illustrates the types of manu-
facturing processes involved in this product area. First, sheet metal
is stamped, blanked, sheared and bent to form the cabinet, chassis,
and front panel sections. These parts are then drilled, punched,
and deburred. The chassis parts are cleaned and plated for protection
and electrical conductivity, while cabinet and front panel parts are
usually cleaned and painted. Electrical and electromechanical
3-812
-------
DRAFT
components are then mounted onto the chassis and front panel/
and two subassemblies are mounted together. Wiring of the
electrical/electromechanical components is performed next.
Finally, the unit is assembled into the cabinet for inter-
connection to the rest of the temperature control system.
-------
DRAFT
PRODUCTION DATA Process controi instruments
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 119
WITH LESS THAN 20 EMPLOYEES 57
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 34 , 500
VALUE ADDED BY MANUFACTURE $595.1 MILLION
VALUE OF SHIPMENTS $845.7 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 50
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 100
4 PHYSICAL PROPERTY MODIFICATION 100
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 100
7 MATERIAL COATING 100
8 ORE PROCESSINGS REFINING 0
9 MOLDING & FORMING - NON-METALS Q
WATER USE
ANNUAL GROSS WATER USE 4.6 BILLION GALLONS
17.41 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 65 . 2
REUSED WATER AS PERCENT OF GROSS USE 34. 8
PERCENT OF ESTABLISHMENTS REUSING WATER 76. 5
PROCESS WATER AS PERCENT OF GROSS USE 32 . 6
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 63.0
PERCENT OF DISCHARGED WATER TREATED 3.45
NA NOT AVAILABLE *Based on Plant Data Collected
TABLE 3-152
3-814
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3-816
-------
DRAFT
Totalizing Fluid Meters and Counting Devices
This segment includes establishments primarily engaged in manufacturi
totalizing (registering) meters, for monitoring fluid flows, such
as watermeters and gasmeters. It also includes producers of mechani-
cal and electromechanical counters and associated metering devices.
The major products are:
Controls, revolution and timing instruments
Counter type registers
Counters: mechanical, electrical, elec-
tronic totalizing
Counters, revolution
Electromechanical counters
Electronic totalizing counters
Gasmeters; domestic, large capacity,
industrial
Gasoline dispensing meters (except pumps)
Gauges for computing pressure-temperature
corrections
Impeller and counter driven flow meters
Integrating meters, nonelectric
Linear counters
Magnetic counters
Measuring wheels
Meters: gas, liquid, tallying, and me-
chanical measuring - except electrical
Odometers
Parking meters
Pedometers
Positive displacement meters
Predetermining counters
Production counters
Propeller type meters with registers
Registers, linear tallying
Rotary type meters, consumption registering
Speed indicators and recorders, vehicle
Speedometers
Tachometer, centrifugal
Tally counters
Tallying meters: except electrical in-
struments, watches, clocks
Tank truck meters
Taximeters
Totalising meters, consumption registering,
except aircraft
-------
Turbine meters, consumption registering
Vehicle tank meters
Watermeters, consumption registering
Fluid meters and counting devices are produced by 56 plants, averaging
150 workers each. Most of these plants (73 percent) employ more than
20 workers. Additional production data are shown in Table 3-153. As
shown in Figure 3-320, 65 percent of the production value is involved
with the production of totalizing fluid meters, while 14 percent is
for counting devices, and 21 percent is for non-electrical motor
vehicle instruments. Various stock metals, motors, tubes, and semi-
conductors are the major identified raw materials. The principal
manufacturing operations are mechanical material removal, material
forming (metal), assembly operations and material coating.
In general, fluid meters and counting devices are made by die cast-
ing or stamping the indicating wheels and cases which are then sur-
face finished, and assembled into the meter. Process water, which
constitutes 33 percent of the gross water used by the industry, is
used mainly for cleaning, plating, and surface finishing operations.
The manufacture of mechanical counting devices (Figure 3-321) is
representative of the fluid meter and counting devices industry.
The shell of the counter is stamped and formed from heavy gauge sheet
stock with a window blanked into the case for viewing of the counter
mechanism. Holes are drilled for mounting bushing blocks, etc. The
counter mechanism wheels are die cast, deburred, and drilled. Numbers
are painted onto the wheel edge and the wheels placed on a length of
steel shaft previously cut to length and drilled. The shaft and wheels
are assembled into the case along with a bottom plate (also previously
stamped). The case is plated inside and the outside is painted. A
molded plastic cover (clear) is installed in the case in front of the
counter wheels to seal the case and insure readability.
3-818
-------
DRAFT
PRODUCTION DATA Fluid meters and counting devices
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 41
WITH LESS THAN 20 EMPLOYEES 15
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 8,400
VALUE ADDED BY MANUFACTURE $182.4 MILLION
VALUE OF SHIPMENTS $283.7 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTINGS MOLDING-METALS 0
2 MECHANICAL MATERIAL REMOVAL 0
3 MATERIAL FORMING - METALS Q
4 PHYSICAL PROPERTY MODIFICATION 0
5 ASSEMBLY OPERATIONS 0
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 100
7 MATERIAL COATING 0
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 0
WATER USE INCLUDES 3823, 3824, 3829
ANNUAL GROSS WATER USE 4.6 BILLION GALLONS
17.411 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 65
REUSED WATER AS PERCENT OF GROSS USE 35
PERCENT OF ESTABLISHMENTS REUSING WATER 76
PROCESS WATER AS PERCENT OF GROSS USE 33
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 63
PERCENT OF DISCHARGED WATER TREATED 3.5
NA ,4O~'~ AvAILALiLfc.
*Based on Plant Data Collected
TABLE 3-153
3-819
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Instruments for Measuring and Testing o^f Electricity and Electrical
Signals"
This segment includes establishments primarily engaged in manufacturing
instruments for measuring the characteristics of electricity and
electrical signals, such as voltmeters, ammeters, wattmeters, watt-
hour meters, demand meters, and equipment for testing the electrical
characteristics of electrical, radio, and communication circuits and
of internal combustion engines. Specific products include:
Alternator and generator testers
Ammeters
Ampere-hour meters
Analog-to-digital converters, electronic
instrumentation type
Analyzers for testing electrical characteristics
Audiometers
Automotive ammeters and voltmeters
Battery testers, electrical
Bleed control cabinets (engine testers)
Bridges: Kelvin, Wheatstone, vacuum tube,
megohm, etc.
Current measuring equipment
Decade boxes: capacitance, inductance, and
resistance.
Demand meters, electric
Diode and transistor testers
Digital panel meters, electricity measuring
Digital test equipment, electronic and electrical
circuits and equipment
Digital-to-analog converters, electronic instrumentation
type
Distortion meters and analyzers
Elapsed time meters, electronic
Electrical power measuring equipment
Electron tube test equipment
Electronic test equipment for testing electrical
characteristics
Energy measuring equipment, electrical
Field strength and intensity measuring equipment,
electrical
Frequency meters: electrical, mechanical, and
electronic
Frequency synthesizers
Function generators
Galvanometers
3-822
-------
DRAFT
Ignition testing instruments
Impedance measuring equipment
Indicating instruments, electric
Instrument relays, all types
Instrument shunts
Instruments, electric: for testing electrical
characteristics
Instruments for measuring electrical quantities
Integrated-circuit testers
Integrating electricity meters
Internal combustion engine analyzers, to test
electrical characteristics
Laboratory standardsf electric: resistance,
inductance, and capacitance
Logic circuit testers
Measuring equipment for electronic and electrical
circuits and equipment
Measuring instruments and meters, electric
Meters, electric: pocket, portable, panelboard,
and graphic recording
Meters, power factor and phase angle
Microwave test equipment
Multimeters
Network analyzers
Ohmmeters
Oscillators, audiofrequency and radio-frequency
(instrument type)
Oscillographs and oscilloscopes
Potentiometric instruments; except industrial
process type
Power measuring equipment, electrical
Pulse (signal) generators
Radar testing instruments, electric
Radio apparatus analyzers, for testing
electrical characteristics
Radio frequency measuring equipment
Radio set analyzers, electrical
Radio tube checkers, electrical
Recorders, oscillographic
Reflectometers, sliding shorts
Resistance measuring equipment
Semiconductor test equipment
Signal generators and averages
Spark plug testing instruments, electric
Spectrum analyzers
Standard cells
Standards and calibration equipment for electrical
measuring, except laboratory
Standing wave ratio measuring equipment
^-823
-------
DRAFT
Stroboscopes
Sweep generators
Sweep oscillators
Synchroscopes
Tachometer generators
Test equipment for electronic and electrical
circuits and equipment
Test sets, ignition harness
Time code generators
Transducers for volts, amperesr watts, vars,
frequency, and power factor
Transformers, instrument: portable
Tube testers
Voltmeters
Volt-ohm milliammeters
Watt-hour and demand meters, combined
Watt-hour and time switch meters, combined
Watt-hour meters, electric
Wattmeters
Waveform measuring and/or analyzing equipment
X-Y recorders (plotters) except computer
peripheral equipment
Instruments to measure electricity are produced by 622 plants,
averaging 87 workers each. Most of these plants (60 percent) employ
less than 20 workers. Additional production data are shown in Table
3-154. As shown in Figure 3-322, 61 percent of the production in
this category is for test equipment for testing electrical, radio,
and communications circuits, while 14 percent is for integrating
instruments, and 25 percent is for miscellaneous test instruments.
Metal mill forms, motors, electron tubes, and semiconductors are
the major raw materials. The principal manufacturing operations are
material forming, assembling operations, chemical/electrochemical
processing, and material coating.
In general instruments for measuring electricity are made by forming
a chassis and cabinet from metal and/or plastic, and then mounting
electronic components and printed circuit boards onto the chassis and
wiring these components to the required electric circuit. Process
water is used mainly for plating and rinsing operations.
3-824
-------
DRAFT
The manufacture of an electronic volt meter is representative of
instruments to measure electricity. As shown in Figure 3-323, sheet
metal is stamped, sheared, and bent to form the chassis, the corners
of which are then spot welded. The chassis is drilled and punched
to accept electrical component mounting. Sheet metal is also stamped,
sheared, bent, folded, and welded to form the outer case of the
instrument.
Electrical components are next mounted on the chassis, printed circuit
boards installed, and interface connectors installed on the front pane
and/or rear chassis apron. The electrical components on the chassis
are then wired together. After fabrication, the case is painted and
trim pieces and handles are installed. The chassis is then installed
into the cabinet and affixed with hardware, usually by machine or
sheet metal screws. The instrument is then tested and calibrated.
3-825
-------
DRAFT
PRODUCTION DATA Instruments to measure electricity
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 251
WITH LESS THAN 20 EMPLOYEES 371
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 53,900
VALUE ADDED BY MANUFACTURE $1,036.9 MILLION
VALUE OF SHIPMENTS $1,531.2 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 0
2 MECHANICAL MATERIAL REMOVAL 80
3 MATERIAL FORMING - METALS 80
4 PHYSICAL PROPERTY MODIFICATION 60
5 ASSEMBLY OPERATIONS 80
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 100
7 MATERIAL COATING 80
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING-NON-METALS 40
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plsnt Data Collected
TABLE 3-154
3-826
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DRAFT
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3-828
-------
DRAFT
Measuring and Controlling Devices, Not Elsewhere Classified
This segment includes establishments primarily engaged in manufacturir
measuring and controlling devices, not elsewhere classified, including
testing instruments to determine the physical properties of materials,
nuclear instruments, aircraft engine instruments, and liquid-in-glass
and bimetal thermometers. The principal products are:
Accelerometers, except aerospace type
Barometers, mercury and aneroid types
Cable testing machines
Compasses, magnetic: portable type
Count rate meters, nuclear radiation
Chronometers, electronic
Dynamometer instruments
Electrogamma ray loggers
Fare registers, for street cars, buses, etc.
Fatigue testing machines, industrial: mechanical
Fire detector systems, nonelectric
Fuel densitometers, aircraft engine
Fuel mixture indicators, aircraft engine
Fuel system instruments, aircraft
Fuel totalizers, aircraft engine
Gauges except electric, motor vehicle: oil pressure,
water temperature
Gauging instruments, thickness: ultrasonic
Geiger counters
Hardness testing equipment
Humidity instruments, except industrial process and
air-conditioning type
Hydrometers, except industrial process type
Hygrometers, except industrial process type
Instrumentation for reactor controls, auxiliary
Ion chambers
Kinematic test and measuring equipment
Level gauges, radiation type
Medical diagnostic systems, nuclear
Moisture density meters, except industrial process
type
Nuclear instrument modules
Nuclear radiation detection and monitoring
instruments
Personnel dosimetry devices
Physical properties testing and inspection equipment
-------
DRAFT
Pressure and vacuum indicators, aircraft engine
Pulse analyzers, nuclear monitoring
Radiation measuring and detecting (radiac) equipment
Salinity indicators, except industrial process type
Sample changers, nuclear radiation
Sealers, nuclear radiation
Scintillation detectors
Spectrometers, liquid scintillation and nuclear
Stress, strain, and flaw detecting and measuring
equipment
Synchronizers, aircraft engine
Temperature sensors, except industrial
process and aircraft type
Testers for checking hydraulic controls on
aircraft
Testing equipment: abrasion, shearing strength,
tensile strength, torsion
Thermocouples, except industrial process and
aircraft type
Thermomagnetic oxygen analyzer
Thermometers, liquid-in-glass and bi-metal type
Thrust power indicators, aircraft engine
Toll booths, automatic
Transducers, pressure
Turnstiles, equipped with counting mechanisms
Ultrasonic testing equipment
Vibration meters, analyzers, and calibrators
Viscosimeters, except industrial process type
Whole body counters, nuclear
Measuring and Controlling Devices NEC are produced by 585 plants,
averaging 38 workers each. Most of these plants (75 percent) employ
less than 20 workers. Additional production data are shown in Table
3-155. As shown in Figure 3-324, the largest production value (36
percent) is in the area of nuclear radiation detection equipment.
Physical property testing equipment is next with 19 percent of the
production value. Aircraft engine instruments and commercial,
meteorological, and general purpose instruments account for the
rest of the production. Stock metals, fractional horsepower motors,
electron tubes and semiconductors are the major raw materials. The
principal manufacturing operations are mechanical material removal,
material forming (metals) of the raw stock metals, and assembly of
component level parts into the final instrument.
A wide range of diverse manufacturing processes are used in the
Measuring and Controlling Devices Industry. This is so mainly
because of the differing raw materials, which are shown in Figure
3-325, and the variety of products, which range from anemometers
to geiger counters. Process water, which constitutes 33 percent
3-830
-------
DRAFT
of the gross water used by the industry, is used mainly for plating,
surface finishing, and cleaning.
Because of the diversity of products and materials used in the
Measuring and Controlling Device industry, no single product can
be considered typical. However, the manufacture of an aneroid
barometer (Figure 3-325) is a good example which utilizes many of
the manufacturing processes in this product area. The mechanical
framework and mechanical linkages are stamped and blanked from sheet
stock. Holes are drilled and, in some cases, bushings are installed
or the hole is tapped. The formed pieces are then cleaned. The
pressure sensing bellows is a metal box with a corrugated top and
bottom. The sides of the box are stamped and welded. The corrugated
top and bottom are made by stamping and forming of sheet stock. They
are then welded (or soldered) to the box sides, and the total box is
evacuated and hermetically sealed. The completed box is clamped to
the barometer frame and a mechanical linkage is soldered to the cente
of the corrugated top. The rest of the linkages are then assembled.
The barometer case is made by slush molding of plastic resins. The
case is machined as required for lens mounting and mechanical inter-
face. The outside is polished, and a scale is painted on the front
of the case. The mechanical workings are then installed and the
barometer is calibrated. A clear plastic or glass lens is installed
on the case front.
-------
DRAFT
PRODUCTION DATA Measuring & controlling devices, nee
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 147
WITH LESS THAN 20 EMPLOYEES 438
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 22,500
VALUE ADDED BY MANUFACTURE $349 MILLION
VALUE OF SHIPMENTS $545.1 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING — METALS 0
2 MECHANICAL MATERIAL REMOVAL 33
3 MATERIAL FORMING - METALS 0
4 PHYSICAL PROPERTY MODIFICATION 0
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS g7
7 MATERIAL COATING 33
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 0
WATER USE COMBINED FIGURES FOR 3823, 3824, 3829
ANNUAL GROSS WATER USE 4.6 BILLION GALLONS
17.411 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 65.22
REUSED WATER AS PERCENT OF GROSS USE 34 . 78
PERCENT OF ESTABLISHMENTS REUSING WATER 76.47
PROCESS WATER AS PERCENT OF GROSS USE 32. 60
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 63.04
PERCENT OF DISCHARGED WATER TREATED 3.45
NA NOT AVAILABLE _. , , r r-r,vprted
*33.sec jn Plant Jat.-^ coixfc' ceu
TABLE 3-',i5
3-832
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-------
DRAFT
Optical Instruments and Lenses
This segment includes establishments primarily engaged in manufacturir
instruments that measure an optical property; apparatus except photo-
graphic that projects or magnifies such as binoculars, prisms, and
lenses; optical sighting and fire control equipment; and related
analytical instruments. Particular products include:
Aiming circles (fire control equipment)
Antiaircraft directors, except electronic
Binoculars
Boards: plotting, spotting, and gun fire
adjustment
Borescopes
Chromatographic equipment (laboratory type)
Chronoscopes
Cinetheodolites
Coddington magnifying instruments
Colorimeters (optical instruments)
Contour projectors
Correctors: percentage, wind, roll (sighting and
fire control equipment)
Coulometric analyzers, except industrial process
type
Dyna-lens
Electron paramagnetic spin type apparatus
Electrophoresis equipment
Fiber optical devices
Fuse setters (fire control equipment)
Glasses, field or opera
Gratings, diffraction
Gun sights, optical
Interferometers
Laboratory analysis instruments, optical
Lens coating
Lens grinding, except ophthalmic
Lens mounts
Lenses, optical: photographic, magnifying, projection,
and instrument
Light sources, standard
Lupes magnifying instruments, optical
Magnifying instruments, optical
Metallographs
Meteorological instruments, optical
Microprobes, electron
Microprojectors
Microscopes, escept corneal
3-835
-------
DRAFT
Mirrors, optical
Nephelometers
Nuclear magnetic resonance" type apparatus
Optical comparators
Optical elements and assemblies, except ophthalmic
Optical measuring instruments
Perimeters (optical instruments)
Periscopes
Ph meters
Photometers
Photomicrographic apparatus
Phototheodolites
Polariscopes
Polarizers
Prisms, optical
Reflectors, optical
Reflectoscopes
Refractometers, except industrial process type
Searchlight mirrors and reflectors
Sighting and fire control equipment, optical
Specific ion measuring instruments
Spectrographs
Spectrometers and spectroscopes, optical instruments
Spyglasses
Telescopes: elbow, panoramic, sighting,
fire control, etc.
Titrometers
Triplet magnifying instruments, optical
Turbidometers
Optical Instruments and Lenses are produced by 482 plants, averaging
38 workers each. Most of these plants (72 percent) employ less than
20 workers. Additional production data are shown in Table 3-156.
As shown in Figure 3-326, 78 percent of the production value is for
analytical, optical, and scientific instruments and 22 percent is
for miscellaneous sighting and fire control systems. Mill shapes
of steel and aluminum are the major raw materials. The principal
manufacturing operations are mechanical material removal, material
forming of the raw materials, and molding and forming (non-metals).
In general,, Optical Instruments are made by fabricating a housing
or other supporting structure to hold the optical elements which
are ground and polished prior to installation in the housing.
Process water, which constitutes 3 percent of the gross water used
3-836
-------
DRAFT
by the industry, is used mainly for plating and cleaning of the
metal parts, and as a suspension medium for grinding and polishing
compounds in making lenses.
The manufacture of binoculars (Figure 3-327) is representative of the
optical instruments and lens industry. Standard commercial prismatic
binoculars are generally manufactured with molded plastic cases and
glass lenses. The various portions of the case are slush molded.
The individual pieces are then deburred and lens and prism mounting
areas are machined for a precise fit. The lenses and prisms are
then ground, polished and mounted in the case. After installation
and adjustment of the lens, the lens retainers are installed and final
adjustments are made in the optic system. Lens covers are then in-
stalled to complete the binoculars.
-------
DRAFT
PRODUCTION DATA Optical instruments and lenses
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 136
WITH LESS THAN 20 EMPLOYEES 346
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 18,100
VALUE ADDED BY MANUFACTURE $375.7 MILLION
VALUE OF SHIPMENTS $525.3 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTINGS MOLDING-METALS 33
2 MECHANICAL MATERIAL REMOVAL 67
3 MATERIAL FORMING - METALS 0
4 PHYSICAL PROPERTY MODIFICATION 0
5 ASSEMBLY OPERATIONS 67
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 0
7 MATERIAL COATING 67
*>
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING-NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE 3.8 BILLION GALLONS
14.383 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 10.53
REUSED WATER AS PERCENT OF GROSS USE 89.47
PERCENT OF ESTABLISHMENTS REUSING WATER 83.3
PROCESS WATER AS PERCENT OF GROSS USE 2.63
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 10.53
PERCENT OF DISCHARGED WATER TREATED 25 . 0
NA NOT AVAILABLE
",=•-• eel on Plant Oa-:a Collected
TABLE 3-156
3-838
-------
DRAFT
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3-840
-------
DRAFT
Surgical and Medical Instruments and Apparatus
This segment includes establishments primarily engaged in manufacturing
medical, surgical, ophthalmic, and veterinary instruments and apparatus
The principal products are:
Anesthesia apparatus
Auriscopes
Biopsy instruments and equipment
Blood pressure apparatus
Blood transfusion equipment
Bone drills
Bone plates and screws
Bone rongeurs
Bronchoscopes
Cannulae
Catheters
Clamps, surgical
Corneal microscopes
Cystoscopes
Diagnostic apparatus, physicians'
Eye examining instruments and apparatus
Fixation appliances, internal
Forceps, surgical
Gastroscopes
Hemodialysis apparatus
Holders, surgical needle
Hypodermic needles and syringes
Inhalation therapy equipment
Inhalators, surgical and medical
Instruments and apparatus: medical,
surgical, ophthalmic, and veterinary
IV transfusion apparatus
Knives, surgical
Metabolism apparatus
Muscle exercise apparatus, ophthalmic
Needle holders, surgical
Needles, suture
Operating tables
Ophthalmic instruments and apparatus
Ophthalmometers and Ophthalmoscopes
Optometers
Otoscopes
Oxygen tents
Peivimeters
Physiotherapy equipment, electrical
-------
DRAFT
Probes, surgical
Retractors
Rifles for propelling hypodermics into
animals
Retinoscopes
Saws, surgical
Skin grafting equipment
Slit lamps (ophthalmic goods)
Speculums
Sphygmomanome te r s
Stethoscopes and stethographs
Suction therapy apparatus
Surgical instruments and apparatus
Surgical knife blades and handles
Tonometers, medical
Trocars
Ultrasonic medical equipment
Veterinarians' instruments and apparatus
Surgical and medical instruments are produced by 487 plants,
averaging 66 workers each. Most of these plants (61 percent)
employ less than 20 workers. Additional production data are
shown in Table 3-157. As shown in Figure 3-328, surgical instru-
ments and hypodermic syringes constitute 40 percent of the pro-
duction and hospital furniture about 11 percent. Raw materials
inclxide metal mill forms, plastics, and fabrics. The principal
manufacturing operations are mechanical material removal, molding
and forming and material coating.
In general, surgical and medical instruments are made by metal work-
ing operations, such as turning, drawing and grinding to form and
finish the raw stock into the desired surgical instrument. Process
water is used mainly for plating, cleaning, and sterilization of
the products.
Because of the diversity of products and materials used in the
surgical and medical instruments industry, no single product can
be considered typical. However, the manufacture of medical scissors
(Figure 3-329) and operating tables (Figure 3-330) illustrate many
of the manufacturing processes used in this industry. Scissors for
medical purposes are stamped from stainless steel sheet stock. The
mating halves are then ground, buffed, and formed. One half section
is drilled and tapped, while the other is clearance drilled for a
mounting screw. The halves are assembled using a machine screw and
-------
DRAFT
the scissors are then cleaned.
Operating room furniture, such as an operating table, is made of
heavy gauge metal for stability. The base is cast and machined at
the mounting surfaces and at the junction of the base and bed
sections. The upper bed portion is die cast, machined at the mount-
ing interface, and buffed. Cross braces are welded to the base and
a sheet plate is welded to the braces as a platform for the mattress,
Holes are then drilled and tapped for control levers, if required,
to rotate or otherwise change the position of the bed. The bed
assembly is completed by plating, and cleaning.
3-843
-------
DRAFT
PRODUCTION DATA Surgical and Medical Instruments and Apparatus
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 192
WITH LESS THAN 30 EMPLOYEES 295
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 31,900
VALUE ADDED BY MANUFACTURE $583.6 MILLION
VALUE OF SHIPMENTS $902.7 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING — METALS 0
2 MECHANICAL MATERIAL REMOVAL 33
3 MATERIAL FORMING — METALS 33
4 PHYSICAL PROPERTY MODIFICATION 0
5 ASSEMBLY OPERATIONS 33
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 33
7 MATERIAL COATING 33
«•
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING — NON-METALS
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE . ^ on Piant L:i, Collected
TABLE 3-K-7
3-844
-------
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DRAFT
Orthopedic, Prosthetic/ and Surgical Appliances and Supplies
This segment includes establishments primarily engaged in manufacturing
orthopedic, prosthetic, and surgical appliances and supplies, arch
supports, and other foot appliances; fracture appliances, elastic
hosiery, abdominal supporters, braces, and trusses; bandages; surgical
gauze and dressings; sutures; adhesive tapes and medicated plasters;
and personal safety appliances and equipment. The principal products
are:
Abdominal supporters, braces, and trusses
Absorbent cotton, sterilized
Adhesive tape and plasters, medicated or non-
medicated
Applicators, cotton tipped
Atomizers, medical
Autoclaves, hospital and surgical
Bandages and dressings, surgical and orthopedic
Bandages: plastic, muslin, plaster of paris, etc.
Belts: sanitary, surgical, and corrective
Braces, elastic
Braces, orthopedic
Bulletproof vests
Canes, orthopedic
Cervical collars
Clothing, fire resistant and protective
Colostomy appliances
Corn remover pads, bunion pads, etc.
Corsets, surgical
Cosmetic restorations
Cotton, absorbent: sterilized
Cotton, including cotton balls, sterile and nonsterile
Crutches and walkers
Drapes, surgical: cotton
Dressings, surgical
Ear stoppers
Elastic hosiery, orthopedic
Extension shoes, orthopedic
First aid, snake bite, and burn kits
Foot appliances, orthopedic
Fracture appliances, surgical
Gas masks
Gauze, surgical: not made in weaving mills
Grafts, artificial: for surgery - made of braided
or mesh artificial fibers
3-848
-------
DRAFT
Gynecological supplies and appliances
Hearing aids
Helmets, space
Hosiery, support
Hydrotherapy equipment
Infant incubators
Intra-uterine devices
Iron lungs
Life preservers, except cork and inflatable
Ligatures, medical
Limbs, artificial
Linemen's safety belts
Models, anatomical
Noise protectors, personal
Orthopedic devices and material
Pads, incontinent and bed
Personal safety appliances and equipment
Plugs, ear and nose
Prosthetic appliances and supplies
Radiation shielding aprons, gloves, sheeting, etc,
Respirators
Respiratory protection equipment, personal
Restraints, patient
Safety appliances and equipment, personal
Safety gloves, all materials
Socks, stump
Space suits
Splints, pneumatic and wood
Sponges, surgical
Sterilizers, hospital and surgical
Stockinette, surgical
Stretchers
Suits, firefighting: asbestos
Supports: abdominal, ankle, arch, kneecap, etc.
Surgical appliances and supplies, except medical
instruments
Suspensories
Sutures, absorbable and nonabsorbable
Swabs, sanitary cotton
Tongue depressors
Traction apparatus
Trusses: orthopedic and surgical
Welders' hoods
Wheelchairs
Whirlpool baths, hydrotherapy equipment
-------
DRAFT
personal fitting to the individual prescription of a physician are
classified in trade industries.
Surgical Appliances and Supplies are produced by .861 plants, averaging
50 workers each. Most of these plants (71 percent) employ less than
20 workers. Additional production data are shown in Table 3-158. As
shown in Figure 3-331, the largest product group in this industry is
surgical, orthopedic, and prosthetic supplies with 69 percent of the
shipment value. Industrial safety devices follow with 20 percent.
The major reported raw materials are cotton fabric and cotton linters.
The principal manufacturing operations are material forming and
assembly of fabric into final configurations, such as surgical corsets,
dressings, etc.; and casting and molding and material forming of metal
to produce artificial limbs, and other surgical and special devices
which involve metal structures.
In general, surgical supplies are made by suitably forming the
component parts of the appliance and joining these parts to form the
finished product. Frequently, sterilization of the product is per-
formed at some stage or manufacture, such as with surgical dressings.
Process water, which constitutes 24 percent of the gross water used
by the industry, is used mainly for sterilization of the finished
products in producing fiber supplies and in the plating and cleaning
of metal products.
*
Because of the diversity of products and materials used in the
surgical appliances and supplies industry, no single product can
be considered typical. However, the manufacture of arch supports
and surgical corsets are good examples of the type of manufacturing
processes used in this industry. Arch supports are produced in
many ways, and two of these are shown in Figure 3-332. Commercially
available arch supports are made by stamping a metal pattern from a
sheet of stainless steel and forming this pattern on a last, and
drilling holes for attaching a soft pad cut from a foam plastic or
rubber sheet. The foam may also be glued to the metal form. The
edges of the steel brace are then ground smooth and buffed to remove
sharp edges.
Custom made arch supports are most commonly made by molding a thermo-
plastic over a plaster mold of the foot. The plastic/ when set, is
ground to conform to the shoe and any sharp edges are removed that
would otherwise annoy the foot.
Surgical corsets (Figure 3-333) are made by cutting cotton or other
fabric to a pattern and joining the pattern pieces by sewing. Re-
inforcement of the corset is achieved by cutting some pattern pieces
at different orientations to the fabric weave, and sewing over the
basic pieces to control the "give" of the sewn corset.
-------
DRAFT
Orthopedic, Prosthetic, and Surgical Appliances
PRODUCTION DATA and supplies
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 249
WITH LESS THAN 20 EMPLOYEES 612
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 43,400
VALUE ADDED BY MANUFACTURE $933.2 MILLION
VALUE OF SHIPMENTS $1444.9 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 0
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 50
4 PHYSICAL PROPERTY MODIFICATION 50
5 ASSEMBLY OPERATIONS 1QO
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 100
7 MATERIAL COATING 50
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 50
WATER USE
ANNUAL GROSS WATER USE 3.4 BILLION GALLONS
12.869 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 58.82
REUSED WATER AS PERCENT OF GROSS USE 41.18
PERCENT OF ESTABLISHMENTS REUSING WATER 46.15
PROCESS WATER AS PERCENT OF GROSS USE 23.53
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
55.88
0
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-158
3-851
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DRAFT
Dental Equipment and Supplies
This segment includes establishments primarily engaged in manufacturer
artificial teeth, dental metals, alloys and amalgams, and a wide
variety of equipment, instruments, and supplies used by dentists,
dental laboratories, and dental colleges. The major products are:
Abrasive points, wheels, and disks:
dental
Autoclaves, dental
Broaches, dental
Burs, dental
Cabinets, dental
Cement, dental
Chairs, dentists'
Compounds, dental
Cutting instruments, dental
Glue, dental
Gold, dental
Hand pieces and parts, dental
Impression material, dental
Investment material, dental
Orthodontic appliances
Plaster, dental
Dental alloys for amalgams
Dental engines
Dental equipment and supplies
Dental laboratory equipment
Dental metal
Denture materials
Drills, dental
Enamels, dentists'
Forceps, dental
Furnaces, laboratory: dental
Pliers, dental
Sterilizers, dental
Teeth, artificial: not made in dental
laboratories
Tools, dentists'
Ultrasonic dental equipment
Wax, dental
-------
DRAFT
Dental equipment and supplies are produced by 427 plants, averaging
29 workers each. Most of these plants (75 percent) employ less than
20 workers. Additional production-data are shown in Table 3-159. As
shown in Figure 3-334, production is evenly divided between dental
supplies and dental equipment. Raw materials are primarily metal
stock, plastics and ceramics. The principal manufacturing operations
involve mechanical material removal, molding and forming (non-metals),
and material coating.
In general, metal dental equipment and supplies are made by metal work-
ing operations, including turning, drawing, grinding, heat treating,
and plating. Chemical preparation of amalgam (filling) and porcelain
compounds are also included in this industry. Process water is used
mainly for plating, cleaning, and rinsing operations.
Because of the diversity of products and materials used in the dental
equipment supplies industry, no single product can be considered
typical. However, the manufacture of dental hand instruments
(Figure 3-335) illustrates the manufacturing processes used in this
industry. Dental hand instruments are made of stainless steel which
is drawn, formed, knurled, turned, bent, and forged to form the re-
quired shape. After the instrument has been formed, it is buffed to
remove any sharp burrs. Then the manufacturers trademark or name is
stamped onto the shank of the tool which is next cleaned to remove
oil and contaminants.
3-856
-------
DRAFT
PRODUCTION DATA Dental Equipment and Supplies
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES
WITH LESS THAN 20 EMPLOYEES
105
322
12,300
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS
VALUE ADDED BY MANUFACTURE $259.7 MILLION
VALUE OF SHIPMENTS $402.4 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS NA
2 MECHANICAL MATERIAL REMOVAL NA
3 MATERIAL FORMING - METALS NA
4 PHYSICAL PROPERTY MODIFICATION NA
5 ASSEMBLY OPERATIONS NA
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS NA
7 MATERIAL COATING NA
8 ORE PROCESSINGS REFINING NA
9 MOLDING & FORMING- NON-METALS NA
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT
* BASED ON PLANT DATA COLLECTED
B,/£ 3-159
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DRAFT
Ophthalmic Goods
This segment includes establishments primarily engaged in manufacturing
ophthalmic frames/ lenses, and sunglass lenses. The principal products
are:
Contact lenses
Eyeglasses, lenses, and frames
Eyes, glass and plastic
Frames and parts, eyeglass and spectacle
Glasses, sun or glare
Goggles: sun, safety, industrial, underwater, etc.
Lens grinding, ophthalmic
Lenses, ophthalmic
Lorgnettes
Magnifiers (readers and simple magnifiers)
Mountings, eyeglass and spectacle
Optical grinding service for the trade
Protectors, eye
Spectacles
Temples and fronts, ophthalmic
Ophthalmic goods are produced by 502 plants, averaging 52 workers
each. Most of these plants (79 percent) employ less than 20 work-
ers. Additional production data are shown in Table 3-160,. The
primary products are eyeglasses and sunglasses, including frames.
Also included are industrial goggles and eye protectors. Figure
3-336 shows the quantity and dollar value of products in this
industry. Glass blanks for lenses and metal and/or plastic for
the frames constitute the major raw materials. The principal manu-
facturing operations are mechanical material removal in forming the
glass lenses and material forming with subsequent chemical process-
ing are used in making metal frames. Plastic frames are made using
injection molding techniques.
In general eyeglass lenses are made by grinding glass lens blanks
using an emery slurry, then rinsing them, polishing them with a
polishing compound (typically a metallic oxide compound). This is
followed by another rinsing and finally edging with a grinding
wheel. Process water, which constitutes 8 percent of the gross
water used, by the industry, is used mainly as a suspension medium
for the grinding and polishing compounds in lens manufacture. It
is also used for plating rinses in the manufacture of metal rims.
-------
DRAFT
The manufacture of eyeglass lenses and frames is representative of
the ophthalmic goods industry. A typical operation for making eye-
glass lenses and frames is shown in Figure 3-337. The glass blanks
are first ground using an emery slurry, then rinsed. Next a polish-
ing operation is performed using a metallic oxide compound. This is
followed by a second rinse. The blank is then edged on a grinding
wheel to obtain a smooth, even edge on the lens.
Plastic eyeglass frames are generally made by injection molding of
plastic formulations. The molded members are polished, and then
assembled with hinge hardware, etc.
Metal frames are fabricated from sheet stock by stamping and bending
operations. The formed sections are then assembled using spot weld-
ing and riveting. Following assembly, the metal is electro finished
using any of several techniques such as plating or anodizing. Plastic
accessories, such as nose rests and ear pads, may be added after sur-
face finishing.
-------
DRAFT
PRODUCTION DATA Ophthalmic Goods
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 104
WITH LESS THAN 20 EMPLOYEES 398
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 26 , 300
VALUE ADDED BY MANUFACTURE $395.8 MILLION
VALUE OF SHIPMENTS $567.9 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING — METALS 0
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 33
4 PHYSICAL PROPERTY MODIFICATION 67
5 ASSEMBLY OPERATIONS 67
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 33
7 MATERIAL COATING 33
8 ORE PROCESSING 8r REFINING 0
9 MOLDING & FORMING — NON-METALS 33
WATER USE
ANNUAL GROSS WATER USE 10.6 BILLION GALLONS
40.121 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 82.08
REUSED WATER AS PERCENT OF GROSS USE 17.92
PERCENT OF ESTABLISHMENTS REUSING WATER 71.43
PROCESS WATER AS PERCENT OF GROSS USE 7 . 55
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 82.08
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE *Based on Plant Data Collected
TABLE 3-160
3-862
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-------
DRAFT
Photographic Equipment and Supplies
This segment includes establishments primarily engaged in manufacturir
(1) photographic apparatus, equipment, parts, attachments/ and
accessories, such as still and motion picture cameras and projection
apparatus; photocopy and microfilm equipment; blueprinting and dia-
zotype (white printing) apparatus and equipment; and other photo-
graphic equipment; and (2) sensitized film, paper, cloth, and plates,
and prepared photographic chemicals for use therewith. Specific
products include:
Aerial cameras
Blueprint cloth or paper, sensitized
Blueprint reproduction machines and
equipment
Brownprint paper and cloth, sensitized
Brownprint reproduction machines and
equipment
Cabinets, cassette film transfer
Cameras, microfilm
Cameras, still and motion picture: all
types
Densitometers
Developers, prepared photographic: not
made in chemical plants
Developing machines and equipment,
still or motion picture
Diazo (whiteprint) paper and cloth,
sensitized
Diazotype (whiteprint) reproduction
machines and equipment
Driers, photographic
Editing equipment, motion picture: re-
winds, viewers, titlers, splicers
Enlargers, photographic
Exposure meters, photographic
Film, sensitized: motion picture, X-
ray, still camera, and special purpose
Fixers, prepared photographic: not
made in chemical plants
Flashlight apparatus for photographers,
except bulbs
Graphic arts plates, sensitized
Hangers: pnotographic film, plate, and
paper
Heat sensitized paper made from pur-
chased paper
-------
DRAFT
Holders: photographic film, plate, and
paper
Lantern slide plates, sensitized
Lens shades, camera
Light meters, photographic
Metallic emulsion sensitized paper and
cloth, photographic
Microfilm equipment: cameras, pro-
jectors, readers, etc.
Motion picture apparatus and equipment
Motion picture film
Photo reconnaissance systems
Photo equipment, all types
Photocopy machines
Photoflash equipment, except lamps
Photographic chemicals, prepared: not
made in chemical plants
Photographic equipment and accessories
Photographic instruments, electronic
Photographic paper and cloth, sensitized;
all types
Photographic sensitized goods
Plates, photographic: sensitized
Printing equipment, photographic
Printing frames, photographic
Processing equipment, photographic
Projectors, still and motion picture:
silent and sound
Range finders, photographic
Reels, film
Screens, projection
Sensitometers, photographic
Shutters, camera
Sound: recording and reproducing
equipment, motion picture
Stands, camera and projector
Stereopticons
Tanks: photographic developing, fix-
ing, and washing
Toners, prepared photographic: not
made in chemical plants
Trays, photographic printing and proc-
essing
Tripods, camera and projector
Washers, photographic print and film
X-ray film
X-ray plates, sensitized
3-866
-------
DRAFT
Photographic equipment and supplies are produced by 616 plants,
averaging 152 workers each. Most of these plants (63 percent)
employ less than 20 workers. Additional production data are shown
in Table 3-161. As shown in Figure 3-338, about 50 percent of the
production is in the area of cameras and equipment, and 50 percent
in the photosensitized material category. A wide range of raw
materials are used in this industry, with details shown in the pro-
duction data in Figure 3-338. The principal manufacturing operations
are chemical processing of film, plastic molding and assembly in the
making of cameras and, mechanical material removal, material forming
(metals) in the manufacture of photographic equipment, such as pro-
jectors, cameras, etc.
A wide range of diverse manufacturing processes are used in the photo-
graphic equipment industry. This is so mainly because of the differ-
ing raw materials, shown in Figure 3-339, and due to the diversity of
products in this industry. Chemical processes are involved in making
film, while plastic molding, metalworking, and lens grinding is in-
volved in making cameras. Process water, which constitutes 12 percent
of the gross water used by the industry, is used mainly for the process
ing of film emulsions and other photosensitized materials, and for
plating and cleaning in the making of cameras.
Because of the diversity of products and materials used in the photo-
graphic industry, no single product can be considered typical. However
the manufacture of negative film and cameras are good examples of the
type of manufacturing processes used in this product area. These manu-
facturing processes are illustrated in Figures 3-339 and 3-340.
Referring to Figure 3-339, film is made by preparing an emulsion of
silver salts, gelatine, and other special purpose chemicals which is
then spread in a thin uniform layer on a clear acetate or other plastic
base. The negative film is then dried and packaged in a variety of
configurations, e.g. sheet, cartridge, roll, etc.
The manufacturing of a camera is a good example of the manufacture of
photographic apparatus (Figure 3-340). In the case of a pocket
type camera (chosen because of the high volume of sales) plastic parts
such as the case, lens, lens cover, etc. are injection molded. Metal
parts, for the shutter, battery contacts, etc. are stamped and formed
to the desired configurations. The parts are then assembled to form
the completed camera.
-------
DRAFT
PRODUCTION DATA Photographic Equipment and Supplies
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 227
WITH LESS THAN 20 EMPLOYEES 389
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 93,500
VALUE ADDED BY MANUFACTURE $4053.2 MILLION
VALUE OF SHIPMENTS $5534.9 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 25
2 MECHANICAL MATERIAL REMOVAL 25
3 MATERIAL FORMING - METALS 25
4 PHYSICAL PROPERTY MODIFICATION 25
5 ASSEMBLY OPERATIONS 25
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 25
7 MATERIAL COATING 75
«•
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE 86 BILLION GALLONS
325.51 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 21.05
REUSED WATER AS PERCENT OF GROSS USE 78.95
PERCENT OF ESTABLISHMENTS REUSING WATER 84.62
PROCESS WATER AS PERCENT OF GROSS USE 12 . 09
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-161
3-868
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Watches/ Clocks, Clockwork Operated Devices, and Parts
This segment includes establishments primarily engaged in manufacturing
clocks (including electric), watches, watchcases, mechanisms for
clockwork operated devices, and clock and watch parts. This industry
includes establishments primarily engaged in assembling clocks and
watches from purchased movements and cases. Principal products are:
Appliance timers
Chronographs, spring wound
Chronometers, spring wound
Clock materials and parts, except crystals and jewels
Clocks, assembling of
Clocks, including electric
Mechanisms for clockwork operated devices
Movements, watch or clock
Timers for industrial use, clockwork mechanism only
Watchcases
Watches and parts: except crystals and jewels
Watches, clocks and watchcases are produced by 202 plants, averaging
157 workers each. About half of these plants (49 percent) employ
more than 20 workers. Additional production data are shown in Table
3-162. As shown in Figure 3-341, the largest product group is clocks,
with a production of over 24 million, followed by watches «(with im-
ported movements) with over 9 million units. Timing motors, watch-
cases and watch movements are the major raw materials. The principal
manufacturing operations are mechanical material removal and material
forming on watch and clock parts, plastic molding operations, electro-
chemical processing and assembly operations.
In general, clocks and watches are made by assembly of precision
mechanical parts into a metal or plastic case that is then equipped
with a face and clear cover. Process water, which constitutes 67
percent of the gross water used by the industry, is used mainly for
plating, machining and cleaning operations.
The manufacture of clocks is representative of the watch and clock
industry. Figure 3-342 descibes the manufacturing operation for
clocks. The plastic case and accessory plastic parts are generally
injection molded. The various timing gears for the clock movement
are produced by stamping (for the larger gears) and by extrusion and
3-872
-------
DRAFT
cutting (for the small, thick gears). Grinding, deburring and
cleaning of the gears precedes assembly. The frame members for
the movement are formed by stamping, blanking and bending oper-
ations. Holes are drilled and tapped, and bushings installed
where required. The movement is then assembled, and a timing
motor (manufactured in-house or purchased) is installed. The
movement is then inserted in the case along with the face and
fastened to the case. Hands, which may be stamped or formed,
are fastened to the movement. A clear plastic lens and bezel
assembly is installed completing the clock. The clock is in-
spected and packaged for shipment.
-------
DRAFT
PRODUCTION DATA Watches, clocks, and watchcases
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 99
WITH LESS THAN 20 EMPLOYEES 103
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 31,700
VALUE ADDED BY MANUFACTURE §506.9 MILLION
VALUE OF SHIPMENTS $995.2 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 0
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 100
4 PHYSICAL PROPERTY MODIFICATION 100
5 ASSEMBLY OPERATIONS 100.
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 100
7 MATERIAL COATING 0
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING- NON-METALS n
WATER USE
ANNUAL GROSS WATER USE 2.7 BILLION GALLONS
10.22 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 81
REUSED WATER AS PERCENT OF GROSS USE 19
PERCENT OF ESTABLISHMENTS REUSING WATER 75
PROCESS WATER AS PERCENT OF GROSS USE 67
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 81
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-162
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DRAFT
Jewelry, Precious Metal
This segment includes establishments primarily engaged ir. rar.ufactur:
jewelry and other articles worn on or carried about the person, made
of precious metals with or without stones (including the setting of
stones where used), including cigarette cases and lighters, vanity
cases and compacts; trimmings for umbrellas and canes; and jewel
settings and mountings. The major products are:
Cases, cigar, cigarette, vanity - pre-
cious metal
Cigar lighters, precious metal
Cigaretle lighters, precious metal
Collar buttons, precious metal and pre-
cious or semiprecious stones
Compacts, precious metal
Cuff buttons, precious metal and pre-
cious or semiprecious stones
Handbags, precious metal
Handles, umbrella and parasol: gold
and silver
Jewel settings and mountings, precious
metal
Jewelry, made of precious metal or precious
or semiprecious stones
Jewelry polishing for the trade
Jewelry soldering, for the trade
Medals, of precious or semiprecious metals
Mountings, gold and silver: for pens,
leather goods, umbrellas, etc.
Pins, precious metal
Rings, precious me^al
Rosaries and other small religious articles,
precious metal
Shirt studs, precious metal and precious or
semiprecious stones
Trimmings for canes, umbrellas, etc. -
precious metal
Watchbands, precious metal
-------
DRAFT
Precious metal jewelry is produced by 1502 plants/ averaging 21
workers each. Most of these plants- (80 percent) employ less than
20 workers. Additional production data are shown in Table 3-163.
As shown in Figure 3-343, the production value of this industry
was $960 million in 1972. Gold, silver, platinum and solder pre-
forms are the major raw materials used to produce rings, necklaces,
brooches, and other jewelry items.
The principal manufacturing operations are material forming, physical
property modification, mechanical material removal, and assembly oper-
ations. In addition, casting is used to obtain intricate patterns
in large items such as class rings.
In general, jewelry is made by forming the basic raw materials into
the desired configurations by casting or other means. Then, a sur-
face treatment such as a precious metal plating is applied. Process
water is used mainly for cleaning prior to and after surface treat-
ments .
The manufacture of a gold class ring (Figure 3-344) is represen-
tative of the precious metal jewelry industry. A gold (alloy) is
melted and poured into a mold to form the crown of the ring. Once
the gold has set, the crown is removed from the mold, deburred and
polished. The surface is then chemically cleaned using a sulfuric
acid pickling solution to remove the black compound formed *on the
ring's surface during casting. A loop is formed around an arbor
and then gold soldered to the crown. A stone is then set into the
crown.
-------
DRAFT
PRODUCTION DATA Jewelry, Precious Metal
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 303
WITH LESS THAN 20 EMPLOYEES 1199
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 31, 700
VALUE ADDED BY MANUFACTURE $166.6 MILLION
VALUE OF SHIPMENTS $327.3 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
I CASTING & MOLDING - METALS 86
2 MECHANICAL MATERIAL REMOVAL 71
3 MATERIAL FORMING - METALS 71
4 PHYSICAL PROPERTY MODIFICATION 43
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 100
7 MATERIAL COATING 28
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS 14
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF UNCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based DP. Plant Data Collected
TABLE 3-t63
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Silverware/ Plated Ware/ and Stainless Steel Ware
This segment includes establishmeats primarily engaged in manufacturing
flatware (including knives, forks, and spoons), hollow ware, toilet
ware, ecclesiastical ware, and related products made of sterling
silver; of metal plates with silver, gold, or other metal; of nickel
silver; of pewter; or of stainless steel. The major products are:
Carving sets: silver, nickel silver, and
stainless steel (all metal)
Cutlery: silver, nickel silver, stainless steel,
and plated (all metal)
Ecclesiastical ware: silver, nickel silver, pewter,
and plated
Flatware: silver, nickel silver, pewter, stainless
steel, and plated
Hollow ware: silver, nickel silver, pewter, stainless
steel, and plated
Loving cups: silver, nickel silver, pewter, and
plated
Silversmithing
Silverware: nickel silver, silver plated, solid
silver, and sterling
Table and kitchen cutlery: silver, silver plated,
and stainless steel
Toilet ware: silver, nickel silver, pewter, and *
plated
Trays: silver, nickel silver, pewter, stainless
steel, and plated
Trophies: silver, nickel silver, pewter, and
plated
Silverware and plated ware are produced by 205 plants, averaging
61 workers each. Most of these plants (65 percent) employ less
than 20 workers. Additional production data are shown in Table
3-164. The major raw materials, as shown in Figure 3-345, are
steel, copper and precious metals. The principal manufacturing
operations are mechanical material removal, material forming and
electrochemical processing.
In general, silverware is made by forming the base metal to the
desired shape by stamping and forming sheet steel and then finish-
ing the metal surface by plating. Process water, which constitutes
12 percent of the gross water used by the industry, is used mainly
for plating and cleaning.
3-882
-------
DRAFT
The manufacture of sterling silver plated knives (Figure 3-346)
is representative of the silverware industry. The blade is first
stamped from stainless steel sheet to the desired configuration.
It is then ground to produce a cutting edge and deburred, if
necessary. The handle is extruded from a silver alloy, such as
nickel silver, to form a hollow shell. One end is closed, while
the other has a slit for the blade. The handle is polished and
then silver plated and the blade is inserted and silver soldered.
Finally, the whole knife is polished.
3-883
-------
DRAFT
PRODUCTION DATA Silverware, Plated Ware, and Stainless Steel Ware
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 71
WITH LESS THAN 20 EMPLOYEES 134
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 12,600
VALUE ADDED BY MANUFACTURE $199.2 MILLION
VALUE OF SHIPMENTS $366.3 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING-METALS 100
2 MECHANICAL MATERIAL REMOVAL 100
3 MATERIAL FORMING - METALS 50
4 PHYSICAL PROPERTY MODIFICATION 50
5 ASSEMBLY OPERATIONS 50
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 50
7 MATERIAL COATING 0
8 ORE PROCESSING & REFINING 0
9 MOLDING & FORMING - NON-METALS Q
WATER USE
ANNUAL GROSS WATER USE 5.2
19.682
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
BILLION GALLONS
BILLION LITERS
92.31
7.69
44.44
11.54
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 75
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3—164
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Jewelers' Findings and Materials/ and Lapidary Work
This segment includes establishments primarily engaged in manufactur
unassembled jewelry parts, and stock shop products such as sheet,
wire, and tubing; and establishments of lapidaries primarily en-
gaged in cutting, slabbing, tumbling, carving, engraving, polish-
ing, or faceting stones from natural or man-made precious or semi-
precious gem raw materials, either for sale or on a contract basis
for the trade; in recutting, repolishing, and setting gem stones;
or in cutting, drilling, and otherwise preparing jewels for instru-
ments, dies, watches, chronometers, and other industrial uses. This
industry includes the drilling, sawing, and peeling of real or
cultured pearls, but does not include the manufacture of artificial
pearls. The major products are:
Diamond cutting and polishing
Diamond points for phonograph needles
Jewel bearings, synthetic
Jewel cutting, drilling, polishing, re-
cutting, or setting
Jewel preparing: for instruments, tools, watches,
and jewelry
Jewelers' findings and materials
Jewelry parts, unassembled
Lapidary work, contract and other
Pearls, drilling of
Pin stems (jewelry findings)
Stones: preparation of real and imitation gems
for settings
Jewelers materials are produced by 563 plants, averaging 14 workers
each. Most of these plants (85 percent) employ less than 20 work-
ers. Additional production data are shown in Table 3-165. As shown
in Figure 3-347, products in this category are about evenly divided
in dollar value between jewelers findings and lapidary work.
Precious and semi-precious metals and precious and semi-precious
gems are the major raw materials. The principal manufacturing oper-
ations are material forming and mechanical material removal.
In general, jewelers findings are made by stamping and forming metal
stock intotdesired shapes. Once the required shape is obtained, part
are usually finish plated and polished. If a gem is added, it is
usually applied with an adhesive after polishing. Process water
is used mainly for cleaning following some forming and plating
operations.
-------
DRAFT
The manufacture of a jewelry chain (Figure 3-348) is representative
of the jewelers findings industry. The chain is generally made from
sheet metal by stamping and forming to shape the links, or it is
made from wire which is cut and twisted into links. The links are
made into a continuous chain and then soldered or brazed at the
junctions. The chain is then plated with a finish metal and polish-
ed for luster.
3-888
-------
DRAFT
PRODUCTION DATA jewelers' materials & lapidary work
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 87
WITH LESS THAN 20 EMPLOYEES 476
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 7,900
VALUE ADDED BY MANUFACTURE $121.4 MILLION
VALUE OF SHIPMENTS $322.8 MILLION
i
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTINGS MOLDING-METALS 50
2 MECHANICAL MATERIAL REMOVAL ^ 50
3 MATERIAL FORMING - METALS 100
4 PHYSICAL PROPERTY MODIFICATION 50
5 ASSEMBLY OPERATIONS ' 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 10°
7 MATERIAL COATING 0
8 ORE PROCESSING & REFINING tf
9 MOLDING & FORMING- NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE NA
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-165
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Musical Instruments
This segment includes establishments primarily engaged in manufacturing
pianos, with or without player attachments; organs; other musical
instruments; and parts and accessories for musical instruments. The
major products are:
Accordions and parts
Autophones (organs with perforated
music rolls)
Banjos and parts
Bassoons
Bells (musical instruments)
Blowers, pipe organ
Bugles and parts (musical instruments)
Calliopes (steam organs)
Carillon bells
Cellos and parts
Chimes and parts (musical instruments)
Clarinets and parts
Concertinas and parts
Cornets and parts
Cymbals and parts
Drummers' traps
Drums, parts, and accessories (musical
instruments)
Flutes and parts
Guitars and parts, electric and non-
electric
Harmonicas
Harps and parts
Harpsichords
Heads, banjo and drum
Mandolins and parts
Marimbas
Mouthpieces for musical instruments
Music rolls, perforated
Music stands
Musical instrument accessories: reeds,
mouthpieces, stands, traps, etc.
Obpes
Ocarinas
Octophones
Organ parts and materials, except
organ hardware
Organs, all types: pipe, reed, hand,
street, barrel, electronic, player
3-892
-------
DRAFT
Piano parts and materials, except piano
hardware
Pianos, all types: vertical, grand,
spinet, player, coin-operated, etc.
Piccolos and parts
Saxophones and parts
Stringed musical instruments and parts
Strings, musical instrument
Trombones and parts
Trumpets and parts
Ukeleles and parts
Vibraphones
Violins and parts
Xylophones and parts
Zithers and parts
Musical instruments are produced by 340 plants, averaging 71 work-
ers each. Most of these plants (68 percent) employ less than 20
workers. Additional production data are shown in Table 3-166. As
shown in Figure 3-349 the yearly production value of musical in-
struments is nearly $100,000,000. A large variety of raw materials
are involved in this industry ranging from wood to precious metals.
The principal manufacturing operations are as varied as the musical
instruments produced. For instance, pianos are primarily manu-
factured by woodworking whereas horns are fabricated by material
forming of brass tubing.
Process water, which constitutes about 16 percent of the gross water
used by the industry, is used mainly for plating operations, rinsing,
and as a lubricant in some metalworking operations.
Because of the diversity of products and materials used in the musical
instrument industry, no single product can be considered typical of
the manufacturing operations performed. However, the manufacture of
pianos and trumpets are good examples. As shown in the process flow
diagram of Figure 3-350, pianos are constructed primarily of wood,
with a cast iron string frame and steel strings. The string frame,
after being cast, is machined as required for mounting to the sound-
ing board, and for proper insertion of the string tension adjustment
pins. The remainder of the construction is primarily woodworking --
cutting, planing, gluing, bolting, etc.
The manufacturing of a trumpet, sho./n in Figure 3-351, is represen-
tative of the manufacturing of bra;-swind instruments in general.
The operation starts with a tube o4*" the base material, usually brass,
which is bent in sections to form the various pieces of the instrument
The valve housings, also made of tubing, are machined to a precision
inside dimension and drilled in appropriate locations for mounting to
the interconnecting tubing. The '^rious tubing sections are then
-------
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brazed to the valves. Another section of tubing is then drawn
and flared to form the bell of the trumpet, and it is brazed to
the pipe section on the horn. The entire instrument is then
plated and polished prior to insertion of the valve mechanisms,
which are machined and finished in a separate operation.
3-894
-------
DfcAFT
PRODUCTION DATA Musical Instruments
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 106
WITH LESS THAN 20 EMPLOYEES 232
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 24,200
VALUE ADDED BY MANUFACTURE $327.5 MILLION
VALUE OF SHIPMENTS $607.2 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING — METALS
2 MECHANICAL MATERIAL REMOVAL
3 MATERIAL FORMING - METALS
4 PHYSICAL PROPERTY MODIFICATION
5 ASSEMBLY OPERATIONS
6 CHEMICAL-ELECTROCHEMICAL OPERA71 ONS
7 MATERIAL COATING
8 ORE PROCESSING & REFINING
9 MOLDING & FORMING — NON-METALS
0
0
0
0
0
0
0
0
0
WATER USE
ANNUAL GROSS WATER USE 0.3 BILLION GALLONS
1.1355 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 100
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER 16.66
PROCESS WATER AS PERCENT OF GROSS USE 16
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
100
NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-166
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DRAFT
Dolls
This segment includes establishments primarily engaged in manufacture
dolls, doll parts, and doll clothing. Establishments primarily en-
gaged in manufacturing stuffed toy animals are also included in
this industry. The major products are:
Animals, stuffed: toy
Dolls, doll parts, and doll clothing
except wigs
Toys, stuffed
Dolls are produced by 243 plants, averaging 43 workers each. Most
of these plants (57 percent) employ less than 20 workers. Addi-
tional production data are shown in Table 3-167. As shown in Figure
3-352, the major raw materials include thermoplastics, fabrics,
paperboard containers and metal mill forms. The principal manu-
facturing operations are plastic molding and assembly operations.
Ir general, dolls are made by molding and assembling plastic parts,
such as heads, arms, legs and trunks, into the finished doll. This
type of manufacturing is essentially dry, however, 50% of the plants
contacted use process water and do not treat it.
The manufacture of dolls, Figure 3-353, is representative of the doll
industry. The various features of the doll, head, arms, torso, etc.
are slush molded. Specific color features for eyebrows, lips, etc.
are hot stamped. The plastic parts are then machined, assembled and
the assembled doll is dressed and then packaged for sale. Kair is
plastic and clothing is purchased either complete or as already
colored material to be made into clothing.
-------
DRAFT
PRODUCTION DATA Dolls
105
138
10,400
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES
WITH LESS THAN 20 EMPLOYEES
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS
VALUE ADDED BY MANUFACTURE $ 96.5 MILLION
VALUE OF SHIPMENTS $199.0 MILLION
5
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING — METALS
2 MECHANICAL MATERIAL REMOVAL
3 MATERIAL FORMING - METALS
4 PHYSICAL PROPERTY MODIFICATION
5 ASSEMBLY OPERATIONS
0
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6 CHEMICAL-ELECTROCHEMICAL OPERATIONS Q
7 MATERIAL COATING
8 ORE PROCESSING & REFINING
9 MOLDING & FORMING-NON-METALS
0
0
0
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-167
3-900
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DRAFT
Games, Toys, and Children's Vehicles; Except Dolls and Bicycles
This segment includes establishments primarily engaged in manufacturim
games and game sets for adults and children, and mechanical and non-
mechanical toys. Important products of this industry include:
Air rifles, toy
Airplanes, toy
Automobiles and trucks, toys
Automobiles, children's
Banks, toy
Baskets, toy
Bells, toy
Blocks, toy
Books, toy: picture and cutout
Carriages, baby
Cars, play (children's vehicles)
Craft and hobby kits and sets
Cycles, sidewalk: children's
Dishes, toy
Doll carriages and carts
Drums, toy
Engines, miniature
Erector sets, toy
Games for children and adults: puzzles,
bingo, marbles, poker chips, chess
Gocarts, children's
Guns, toy
Hobbyhorses
Horns, toy
Kites
Magic lanterns (toys)
Models, toy and hobby: airplane, boat,
ship, railroad equipment, etc.
Musical instruments, toy
Paint sets, children's
Pistols, toy
Poker chips
Rocking horses
Scooters, children's
Sleds, children's
Strollers, baby (vehicles)
Structural toy sets
Sulkies, baby (vehicles)
Tenders, baby (vehicles)
-------
DRAFT
Toys: except dolls, children's vehicles,
and rubber toys
Trains and equipment, toy: electric and
mechanical
Tricycles
Vehicles except bicycles, children's
Velocipedes
Wagons, children's: coaster, express,
and play
Walkers, baby (vehicles)
Games, toys and childrens vehicles are produced by 649 plants,
averaging 93 workers each. Most of these plants (58 percent)
employ less than 20 workers. Additional production data are shown
in Table 3-168. As shown in Figure 3-354 metal mill shapes, plastics
fabrics and paperboard containers are the major raw materials. The
principal manufacturing operations are mechanical material removal,
material forming, plastic molding, and material coating.
A wide range of diverse manufacturing processes are used in the game,
toys and children's vehicles industry. This is so mainly because of
the differing raw materials which are shown in Figure 3-355 and to
the diversity of finished products in this category. Process water,
which constitutes 7 percent of the gross water used by the industry,
is used mainly for plating and cleaning of metal parts.
Because of the diversity of products and materials used in the games,
toys and children's vehicles industry, no single product can be con-
sidered typical. However, the manufacture of wagons is a good ex-
anple of the manufacturing operations performed in this industry.
The body of the wagon is stamped from a piece of sheet metal stock,
then bent and formed to make the sides and lip of the body. The
body is drilled to accept mounting hardware, then cleaned and painted
Brackets for the wheels are stamped, bent, formed, drilled and paint-
ed. Steel tube or rod is cut to length to form axles. The handle is
stamped, formed and rolled and then riveted to the front wheel assemb!
Plastic wheels are molded, and nylon bushings inserted into the wheel
hub. Assembly is most frequently left to the purchaser, so the final
production step is packaging of the individual components. Nuts,
bolts and sheet metal screws are used in assembling a wagon.
3-904
-------
DRAFT
PRODUCTION DATA GaneE/ tcySi and children's vehicles
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 272
WITH LESS THAN 20 EMPLOYEES 377
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 60,200
VALUE ADDED BY MANUFACTURE $ 947.7 MILLION
VALUE OF SHIPMENTS $1683.8 MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING a MOLDING - METALS 0
2 MECHANICAL MATERIAL REMOVAL 0
3 MATERIAL FORMING - METALS IQO
4 PHYSICAL PROPERTY MODIFICATION 0
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS o
7 MATERIAL COATING ]_00
8 ORE PROCESSINGS REFINING 0
9 MOLDING & FORMING - NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE i.s BILLION GALLONS
5.677 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 60
REUSED WATER AS PERCENT OF GROSS USE 40
PERCENT OF ESTABLISHMENTS REUSING WATER 62.5
PROCESS WATER AS PERCENT OF GROSS USE 6.66
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 60
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE
*Based on Plant Data Collected
TABLE 3-168
-------
DRAFT
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DRAFT
Sporting and Athletic Goods, Not Elsewhere Classified
This segment includes establishments primarily engaged in manufacturing
sporting and athletic goods, not elsewhere classified, such as fish-
ing tackle; golf and tennis goods; baseball, football, basketball,
and boxing equipment; roller skates and ice skates; gymnasium and
playground equipment; billiard and pool tables; and bowling alleys
and equipment. The principal products are:
Ammunition belts, sporting type: of all materials
Archery equipment
Arrows, archery
Athletic and sporting goods: except clothing,
firearms, and ammunition
Badminton equipment
Bait, fishing: artificial
Balls: baseball, basketball, football, golf, tennis,
pool, and bowling
Baseball equipment and supplies, except uniforms
Bases, baseball
Basketball equipment and supplies, except uniforms
Baskets, fish and bait
Bats: baseball, cricket, etc.
Billiard and pool balls, cues, cue tips, and tables
Billiard chalk
Boomerangs
Bowling alleys and accessories
Bowling pin machines, automatic
Bowling pins
Bows, archery
Boxing equipment
Bridges, billiard and pool
Buckets, fish and bait
Cartridge belts, sporting type
Cases, gun and rod (sporting equipment)
Creels, fish
Cricket equipment
Croquet sets
Decoys, duck and other game birds
Dumbbells
Exercising machines
Fencing equipment (sporting goods)
Fishing tackle (except lines, nets, and seines)
Flies, artificial: for fishing
Floats, for fish lines
-------
DRAFT
Footballs and football equipment, and supplies,
except uniforms '
Game calls
Gloves, sport'and athletic: boxing, baseball,
handball, etc.
Golf carts, hand
Golfing equipment: caddy carts and bags, clubs,
tees, balls, etc.
Guards: football, basketball, soccer, lacrosse,
etc.
Gymnasium, and playground equipment
Helmets, athletic
Hockey equipment, except uniforms
Indian clubs
Lacrosse equipment
Mallets, pole, croquet, etc.
Masks: baseball, fencing, hockey, etc.
Nets: badminton, basketball, tennis, etc. -
not made in weaving mills
Pads: football, basketball, soccer, lacrosse,
etc.
Pigeons, clay (targets)
Pin setters for bowling, automatic
Playground equipment
Polo equipment, except apparel
Pool balls, pockets, tables, and equipment
Protectors: baseball, basketball, hockey,
etc.
Rackets and frames: tennis, badminton, squash,
lacrosse, etc.
Scoops, crab and f;sh
Shafts, golf clubs
Shooting equipment, except firearms and ammunition
Sinkers (fishing tackle)
Skates and parts, ice and roller
Skin diving equipment, scuba type: except clothing
Skis and skiing equipment, except apparel
Snowshoes
Soccer equipment, except apparel
Spears, fishing
Sporting goods: except clothing, firearms,
• and ammunition
Squash equipment, except apparel
Sticks: hockey, lacrosse, etc.
Striking (punching) bags
Strings, tennis racket
Swimming pools, plastic
Tables: billiard, pool, bagatelle, and ping pong
Target shooting equipment, except firearms and ammunition
-------
Targets, archery and rifle shooting
Targets, clay
Tennis goods: balls, frames, rackets, etc.
Toboggans
Track and field athletic equipment, except
apparel
Trap racks (clay targets)
Wading pools, plastic coated fabric
Sporting and Athletic Goods NEC are produced by 1529 plants, averaging
39 workers each. Most of these plants (70 percent) employ less than
20 workers. Additional production data are shown in Table 3-169.
As shown in Figure 3-356, a wide range of raw materials are used in
the manufacture of sporting goods because of the wide array of finished
products. Stock metals, plastics, broadwoven fabrics, and leather
are the major raw materials. The principal manufacturing operations
are determined by the product and range from casting and molding of
plastics to mechanical material removal and material forming of
metal.
A wide range of diverse manufacturing processes are used in the
sporting and athletic goods industry. This is so mainly because
of the differing raw materials, which are shown in Figure 3-356
and because of the diversity of products in this category. Process
water is used mainly for plating and cleaning at various .stages of
manufacture of such products as golf clubs, fishing tackle, etc.
Because of the diversity of products and materials used in the
sporting and athletic goods industry, no single product can be
considered typical. However, the manufacture of golf clubs and
swimming pools are good examples of the type of manufacturing
processes used in this industry. Golf club manufacture, as
illustrated in Figure 3-357, starts with the shaft which is usually
made of steel tubing which is pickled, rinsed, heat treated, drawn,
cut, tempered, cleaned, plated, and cleaned again. The head of the
club is forged or cast and machined. It is then drilled to fit the
shaft, heat treated, plated, and cleaned. The head and shaft are
joined to form the club, and a handle grip is added. Then it is
balanced, polished, inspected, and tested.
Swimming pools (above ground, over 15 foot diameter, metal), as illus-
trated in Figure 3-358, are made from various mill forms or sheet metal,
usually steel. The wall sections are sheet steel which is sheared,
punched, stamped, blanked, cleaned, and painted. The bracing members
of the framework of the pool are built up with angular stock, tubing,
and rolled sheet stock. Rolled sheet metal forms the top edge of the
pool and all metal parts are painted. The vinyl liner is made by
calendering vinyl into a large continuous sheet of the appropriate
size for the pool. The liner is a purchased item for many of the
pool manufacturers.
-------
DRAFT
PRODUCTION DATA Sporting and Athletic Goods, Not Llsewhere Classified
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 451
WITH LESS THAN 20 EMPLOYEES 1078
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 60,200
VALUE ADDED BY MANUFACTURE $ 905.1 MILLION
VALUE OF SHIPMENTS $1701.3 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 0
2 MECHANICAL MATERIAL REMOVAL ; 5
3 MATERIAL FORMING - METALS iQO
4 PHYSICAL PROPERTY MODIFICATION 25
5 ASSEMBLY OPERATIONS 100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 50
7 MATERIAL COATING 100
8 ORE PROCESSINGS REFINING 0
9 MOLDING & FORMING - NON-METALS 25
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE NA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
NA NOT AVAILABLE
*Based on Plant Dato Collecte
TABLE 3-169
3-')l 1
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3-914
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DRAFT
Pens, Mechanical Pencils, and Parts
This segment includes establishments primarily engaged in manufacturing
pens, pen points, fountain pens, ball point pens, refill cartridges,
porous tipped felt tip markers, and parts. The major products are:
Cartridges, refill: for ball point pens
Fountain pens and fountain, pen desk sets
Markers, soft tip (felt, fabric,- plastic,
etc.)
Meter pens
Nibs (pen points): goldf steel; or other
metal
Per, points: gold, steel, or other metal
Pencils and pencil parts, mechanical
Penholders and parts
7'ans and pen pares: fountain, sr.vlcqrapMc
?nd ball point
Pe-s ana n,sc;?^;i: :ral pencJIs ?re >:rDdijca.;'. by llf yiar-tr,, averaging
liJ v")o-'-er-s each, Most -•?_ these, p'^nts (55 percent) employ rcore
th'-n 20 v..xJ.erSc A6o.iticMc 1 prr-ouctio-- flata are snown in Table.
3-lT'O, As shc.wn in Fig-j.re 3-35S-- over 3 billic* pers were produced
:.r. the J. I;, .vt 1372. Kav. matfvic-ls- are Tietals -including some
azotic rietalss . plastics and gun- f'^r srasejrs. lr.e p.,incipa] niaiiu-
'.aci:ui*r.:g e;-s;.av.ions are mechan:'Ccl m--;"er''.al removal pic.?tic nold-
ir.g anc1 esseyOiy operations.
~>.ii general- psnc and mec'".s.riccLl pencils ere rno.c t ::y n ttr.oo, scamp-
ing; swaging anc: crirapin^, mete Is cV:ici plastic tc rcrr: • he --'^SF to
v;hich 5.L- aoosd c. lead or inr c? -."." .\ldcs, Process, warer is used main-
;.y for pis ting 5^.5 cJ.-3aiii';-gf x-:'.':'i c rr.inor amour t used in metal work-
ing along with a lubricating oilt
The T.aivufactu.re of ball r-civc pans (F:.'-r::e 2-360; is representative
of the pens f.nd mechanical pencil industry. The case of v,he pen is
slush r.olded of clear or color£-5 (as dseirec) plastic. The ink con-
tainer is a section of extruced plastic tube with a tip assembly in-
stalled in one end. The top assembly is the key to the pen's oper-
ation and is manufactured by extruding and forming a case (usually
brass) to which is installed an iridium ball bearing. A stop is
placed behind the base to prevent its slipping out of the case.
The plastic ink tube is attached to the tip and filled with ink.
Then the tip assembly along with ink tube is installed into the
molded case.
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DRAFT
PRODUCTION DATA pens and mechanical pencils
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20
WITH LESS THAN 20
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS
VALUE ADDED BY MANUFACTURE $215.1
EMPLOYEES 64
EMPLOYEES 52
13,800
MILLION
VALUE OF SHIPMENTS $310.2 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS
2 MECHANICAL MATERIAL REMOVAL
3 MATERIAL FORMING - METALS
4 PHYSICAL PROPERTY MODIFICATION
5 ASSEMBLY OPERATIONS
0
100
100
100
100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 100
7 MATERIAL COATING
8 ORE PROCESSING 8r REFINING
9 MOLDING & FORMING - NON-METALS
100
0
100
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
NA
NA
NA
NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
«
PERCENT OF DISCHARGED WATER TREATED
NA NOT AVAILABLE
TABLE 3-170
3-916
NA
NA
* BASED ON PLANT DATA COLLECTED
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DRAFT
Costume Jewelry and Costume Novelties, Except Precious Metal
This segment includes establishments primarily engaged in manufacturing
costume jewelry, costume novelties, and ornaments made of all materials
except precious metal, precious or semi-precious stones, and rolled gol
plate and gold filled materials. The major products include:
Compacts, except precious metal and solid
leather
Costume jewelry, except precious metal and
precious or semiprecious stones
Novelties, costume: except precious me-cal
and gems
Ornaments, costume: except precious metal and •
gems
Pearls, artificial
Rings, finger: gold plated wire
Rosaries and other small religious articles,
except precious metal
Vanity cases, except precious metal and
leather
Watchbands, base metal
Costume jewelry is produced by 76? plants, averaging 28 workers
each. Most of these plants (73 percent) employ less than 20 work-
ers. Additional production data are shown in Table 3-171. Figure
3-361 shows the production value of this industry. Costume jewelry,
including rings, necklaces, chains, and other personal items are
manufactured from base metals, possibly with a semi-precious metal
plate, and frequently with non-precious stones affixed to the :'cem.
The principal manufacturing operations are material forming, physical
property modification, casting and molding (metals), mechanical
material removal and assembly operations.
In general costume jewelry is made by forming the basic raw materials
into the desired configurations by casting or other mechanica] form-
ing means. The formed piece is then surface treated with such
materials as chrome or silver plating. Process water, which con-
stitutes 60 percent of the gross water used by the industry, is used
mainly during plating, rinsing, and surface cleaning operations.
The manufacture of a ring (Figure 3-362) is representative of the
costume jewelry industry. The base metal is initially melted and
poured into a mold to form the crown of the ring. Once the poured
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DRAFT
metal has set, the crown is removed from the mold, debarred, and
polished. A loop of the base metal is then formed around an arbor
and soldered to the crown. The entire ring is next chemically
cleaned to remove flux and other impurities from the surface. The
ring is then plated with a finish metal (e.g. silver), and polished.
3-920
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DRAFT
PRODUCTION DATA Costunie Jewelry and Costume Novelties,
PRODUCTION DATA Fxcept precicu£ Metal
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES 205
WITH LESS THAN 20 EMPLOYEES 557
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS 21,500
VALUE ADDED BY MANUFACTURE $281,3 MILLION
VALUE OF SHIPMENTS $^79.0 Mi
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING & MOLDING - METALS 50
? MECHANICAL MATERIAL REMOVAL 2b
3 MATERIAL FORMING - METALS 25
4 PHYSICAL PROPERTv MODIFICATION C
5 ASSEMBLY OPERATIONS 50
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 75
7 MATERIAL COATING C
8 ORE PROCESSING & REFINING 0
S MOLDING 8: FORMING — NON-METALS 0
WATER USE
ANNUAL GROSS WATER USE 0.5 BILLION GALLONS
1.69 BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE 80
REUSED WATER AS PERCENT OF GROSS USE 20
PERCENT OF ESTABLISHMENTS REUSING WATER 50
PROCESS WATER AS PERCENT OF GROSS USE 60
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE 60
PERCENT OF DISCHARGED WATER TREATED NA
NA NOT AVAILABLE *BASED ON PLANT DATA CCllICTED
TABLE 3-171
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Brooms and Brushes
This segment includes establishments primarily engaged in manufacturing
household/ industrial, and street sweeping brooms; and brushes. The
major products are:
Artists' brushes, hand
Brooms, hand and machine: bamboo, wire, fiber,
splint or other material
Brushes for vacuum cleaners, carpet sweepers,
and other rotary machines
Brushes, household and industrial
Hair pencils (artists' brushes)'
Paint brushes
Paint rollers
Push brooms
Shaving brushes
Street sweeping brooms, hand and machine
Toilet brushes
Toothbrushes, except electric
Varnish brushes
Whisk brooms
Brooms and brushes are produced by 446 plants, averaging 39 work-
ers each. Most of these plants (63 percent) employ less than 20
workers. Additional production data are shown in Table 3-172.
As shown in Figure 3-363, the bulk of the industry production is
in the areas of paint brushes and "other" (personal and artists)
brushes. These comprise 77 percent of the dollar value production.
Mill forms, nylon and boar bristle, wood and plastic are the major
raw materials. The principal manufacturing operations are mechanical
material removal, material forming, and plastic molding.
In general, brooms and brushes are made by installing bristles on a
handle. Both the bristles and handles vary with the type of brush
being produced. Process water is used mainly for plating and clean-
ing.
Because of the diversity of products and materials used in the brooms
and brushes industry, no single product can be considered typical.
However, the manufacture of twisted wire brushes, as shown in Figure
3-364, is 'a good example of the manufacturing processes used in this
industry. A length of wire (of suitable gauge) is first plated
to resist corrosion. It is then folded. Bristles are placed between
a portion of the parallel folded wire, and the wires are tightly twisted
in a special twisting machine fixture to tightly hold the bristles and
add strength to the brush. A plastic or wood piece is-then mounted on
the end of the twisted wire to form the brush handle.
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DRAFT
PRODUCTION DATA Brooms and Brushes
NUMBER OF
NilMRFR OF
ESTABLISHMENTS, WITH MORE THAN 20 EMPLOYEES
WITH LESS THAN 20 EMPLOYEES
FMPLfWFFS Al 1 FRTAR1 ISHMFNTS
' ' 164
282
17 e. ii r,
VALUE: ADDED BY MAISSUFACTURE $234.6 MILLION
VALUE OF SHIPMENTS $437.2 MiLLSOi'
Pll^CFHT Or ESTABLISHMENTS USING VA«iC',S fv^i'!UFACT!,miN3 OPERATIONS,
1 CASTING 'i MOLDING - METALS 0
2 MEX ;-:AN!CA!_ MATERIAL REMCV.-'L 0
:; vi/'T^.RiAL FORMING — METALS 100
4 .'-hYSICAL FDROPEi7TV MOCtFiC/.'. '•. ;-J C
5 ASSEMBLY OPERATIONS 100
6 CKEf/aOAL-ELECTROCKEr-.IICA:. ."PERATEOHS 0
: :.'.\T::RIAL COATING •;.
'!, ORE PROCESSING & RLl-'iNsNG 0
9 MOLDING at OR-vlING — NOH—MJn -'. S 0
a-\NU/'!. -5ROSP WATER 'JSE NA P'.LL.'ON GALLj;
:;a BILLION LITEF.S
INTAKE WATER AS PERCENT OF GROSS USE NA
REUSED WATER AS PERCENT OF GROSS USE HA
PERCENT OF ESTABLISHMENTS REUSING WATER NA
PROCESS WATER AS PERCENT OF GROSS USE NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
NA
NA NOT AVAILABLE
* BASED ON PLANT r.-.T.-. COLLECTED
TABLE 3-172
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DRAFT
Signs and Advertising Displays
This segment includes establishments primarily engaged in manufacturing
electrical, mechanical, cutout or plate signs and advertising displays,
including neon signs and advertising novelties. The principal products
are:
Advertising displays, except printed
Advertising novelties
Cutouts and displays, window and lobby
Displays, paint process
Electrical signs and advertising dis-
plays
Letters for signs, metal
Name plates, metal: except engraved,
etched, etc.
Neon signs
Scoreboards, electric
Signs, not made in custom sign painting
shops
Signs and advertising displays are produced by 3261 plants, averaging
15 workers each. Most of these plants (81 percent) employ less than
20 workers. Additional production data are shown in Table 3-173.
The overall production value in this industry is shown in figure 3-365.
All types of advertising displays, except electrical signal and
commercial lighting, are included in this category with neon signs,
wooden signs and metal painted signs the most common. A wide range
of raw materials are used including metal, plastics, wood, glass,
paper, electrical wiring and coating materials. The principal manu-
facturing operations are material forming, mechanical material re-
moval, assembly operations and material coating.
In general, displays are made by cutting the various component parts
of the display (plastic, metal, wood, etc.) to the desired form and
joining these parts to form the finished product. Other parts such
as lighting fixtures may be added. Process water is used mainly
during plating and cleaning operations.
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DRAFT
Because of the diversity of products and materials used in the dis-
play industry, no single product can be considered typical. How-
ever, the manufacture of wife display racks (Figure 3-366) illustrates
some of the manufacturing processes used in this category. Initially,
steel rod is cut and bent to form the perimeter of the rack. A light-
er gauge rod is than cut and bent to form cross braces. Following
this, metal wire is cut and bent to form the hangers and other assort-
ed braces to support the main rack. The various sections of wire
braces and rods are assembled using fixtures and spot welded together
at each junction point. Finally, the assembled rack is bright dipped
and plated.
f
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DRAFT
PRODUCTION DATA Marking devices
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20
WITH LESS THAN 20
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS
VALUE ADDED BY MANUFACTURE $ 736.
EMPLOYEES 623
EMPLOYEES 2638
49,100
1 MILLION
VALUE OF SHIPMENTS $1181.4 MILLION
*
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTINGS MOLDING -METALS
2 MECHANICAL MATERIAL REMOVAL
3 MATERIAL FORMING - METALS
4 PHYSICAL PROPERTY MODIFICATION
5 ASSEMBLY OPERATIONS
0
40
20
0
80
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 0
7 MATERIAL COATING
8 ORE PROCESSING & REFINING
9 MOLDING & FORMING - NON-METALS
100
0
0
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
NA
NA
NA
NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
NA NOT AVAILABLE
TABLE 3-173
3-930
NA
NA
* BASED ON PLANT DATA COLLECTED
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DRAFT
Burial Caskets
This segment includes establishments primarily engaged in manufacturing
burial caskets and cases including shipping cases of wood or other
material except concrete. Specific products are:
Burial cases, metal and wood
Burial vaults, fiberglass
Casket linings
Caskets, metal and wood
Grave vaults, metal
Caskets are produced by 505 plants, averaging 29 workers each.
Most of these plants (64 percent) employ less than 20 workers.
Additional production data are shown in Table 3-174. As shown
in Figure 3-367, metal caskets comprise almost half of the pro-
duction and over half of the dollar value of this industry. Wood
and "other" types of caskets account for the remainder of the pro-
duction in this industry. Metal mill forms, wood, fiberglass, and
fittings are the major raw materials. The principal manufacturing
operations are material forming, mechanical material removal, assembly
operations and material coating.
In general, caskets are made by cutting the pieces of the shell and
then forming these pieces. These shell pieces are then joined to
form the completed casket shell and plated. Casket linings of cloth
material are next placed inside the casket shell. Hardware such as
handles and ornamentation can be cast, forged or rolled to the de-
sired shape or form and then plated to finish the piece. Process
water is used mainly for plating and cleaning operations.
The manufacture of a metal casket shell (Figure 3-368) is represent-
ative of the casket industry. First, the sides, ends, bottom, and
cover are stamped from sheet stock and then formed to their final
shapes. The shell is then assembled and the seams welded. The cover
and shell are then pickled and plated. Frequently epoxy is applied
by a dipping process. For preservation, the cover is attached to the
shell with hinges and the interior is fitted and decorated as desired.
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DRAFT
1
PRODUCTION DATA , . . , .
burial caskets
NUMBER OF ESTABLISHMENTS, WITH MORE THAN 20
WITH LESS THAN 20
NUMBER OF EMPLOYEES ALL ESTABLISHMENTS
VALUE ADDED BY MANUFACTURE $207.3
VALUE OF SHIPMENTS $385.3
EMPLOYEES 183
EMPLOYEES 322
14,600
MILLION
MILLION
PERCENT OF ESTABLISHMENTS USING VARIOUS MANUFACTURING OPERATIONS,
1 CASTING a MOLDING - METALS
2 MECHANICAL MATERIAL REMOVAL
3 MATERIAL FORMING - METALS
4 PHYSICAL PROPERTY MODIFICATION
5 ASSEMBLY OPERATIONS
0
0
0
0
100
6 CHEMICAL-ELECTROCHEMICAL OPERATIONS 0
7 MATERIAL COATING
8 ORE PROCESSING a REFINING
9 MOLDING a FORMING - NON-METALS
50
0
0
WATER USE
ANNUAL GROSS WATER USE NA BILLION GALLONS
NA BILLION LITERS
INTAKE WATER AS PERCENT OF GROSS USE
REUSED WATER AS PERCENT OF GROSS USE
PERCENT OF ESTABLISHMENTS REUSING WATER
PROCESS WATER AS PERCENT OF GROSS USE
MA
NA
NA
NA
WASTE WATER
DISCHARGED WATER AS PERCENT OF GROSS USE
PERCENT OF DISCHARGED WATER TREATED
NA NOT AVAILABLE
TABLE 3-174
3-934
NA
NA I
* BASED ON PLANT DATA COLLECTED
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U.S. ENVIRONMENTAL PROTECTION AGENCY (A-107)
WASHINGTON, D.C. 20460
POSTAGE AND FEES PAID
ENVIRONMENTAL PROTECTION AGENCY
EPA-335
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