-------
DRAFT
_
U) bi 111
IPS
it. at m
in
a
H
O
UI
m
in
u>
U)
j
a:
z t
g £
u. i/i
£
e
in
m
in
in
j
1- d _i
ui £ in
ui < in
i 1- I-
i/> tn ID
-------
DRAFT
Ul
O
I i; ui
mom
= 0:0:
5 = 0
u. in u
UJ
o
a:
£
z
UJ
cc
Ul
in
Ul
m
2
Ul
in
in
ui
H
<
Z
UJ
a:
O
O
Z
E
D
u
<
U.
D
Z
I-
UJ
in
a:
o
o
j
<
u
(5
o:
3
(O
CO
CO
o
Ul
K
D
82
H a:
h CD
o <
u u.
3-854^
-------
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
-------
DRAFT
EH
CJ
D
Q
o
fc,
O
05
^
2
U
g
O<
H
K
U3
h
O
ra -o - co
.H C H C -rl
a a at c o
4-1 4J O -rl »
(U - C -H JJ 10
g (0 4) rH O M
H ^ H p (8
H 10 -iH "O rH
ID iH M g O «-l
-P .-I i
ii
_i a:
-1 H
uj (n
U D
U) Q
f s
UJ
a:
D
U3
O
U
<
z
•a
n
o
u
(U
a:
O
Z
U
EH
3-858
-------
DRAFT
0
UJ
ffl
1
FORM
DRAW
KNURL
TURN
f,
£ EE
< UJ
n: i-
<
FINISHED
INSTRUMENT
f
INSPECT
1
CLEAN
1
STAMP
|
IL
U.
m
1
FORGE
I
-------
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
-------
DRAFT
to
t-1
a
a
g
p.
S'
U)
£
w
s
w
I
>-H
O C
a
O
H
U
Q
s
cs
o
ml
a
2
O
U
O
O
0)
a
il
<
X
2
-------
DRAFT
o
LI
I
in
z
C
in
iu
in
in
<
_j
0
SK
Ul
iu p
j i-
m ,
z £
LI U
in ;
in i
D
j UJ
f) 2
*- <
u o:
< -1 U.
D
Z
LI
O
*
ASSEMBLE
RIVET & WELD
-
SURFACE
TREAT
*
PLASTIC
TRIM
*
1 INSPECT
*
FINISHED
METAL
FRAMES
FINISHED
PLASTIC
FRAMES
*
ASSEMBLE
*
HINGE
PARTS
-
.in 5
-------
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
-------
DRAFT
Q
o
o
(A
H
01
.-I
(0 ID
-P >
•rl
>H JJ 10
O -H ^
I* (B
H .H
ID H
C C
C O
•O -H -H
X
03
14
C! (V
-o
r- o
^ 00
^ •*
- n
m *-^
U>'-^
X to
C
(T\ O
\& H
o <;
^ o ^^
&\ in 2
ro m
o -
-m
ro —
10
4J
-H
C
p
ie£
o \
o z
o
^
o
0
to
JJ
-H
C
a
C
o
•H
r-<
1-1
•^
W-'^
^ N
O
m
vc O
*» o
-o
rH -
CO O
ON O
^ CS
rH -
<
s.
z
co
§
u
I
a
o
u
n w
0 >,
a, o
10
(Ti
C
-r^
43
at
«
0)
HI
3
H
C
O
<-!
W
J
-------
DRAFT
;
i
;
E
i
t
<
^
i
c
L
0
0
j
X
i
o
LU
•£.
tn
j
a
J
'
j
.
E
u
C
'.
3
j
e
L
ILVER NITRATE
OTASSIUM OR
MMONIUM HALIDE
(/) Q. <
FINISHED
FILM NEGATIVE
;
01
a
'
i
o
)
FINAL
ADDITIONS
1
WASH
1
_J
_J
0 2 v I
I I 1 i
O
o
tn
1 P
n 5
1 S
z
o:
D
h
U
<
LL
r>
z
<
LJLJ
5
LU
Z
o>
CO
r*>
CO
o:
3-870
-------
DRAFT
ASE
IC
S
FINISHED C
AND PL
PARTS
FINISHED
LENS
o:
lu
O Q
I Z h- O
a < o o
Ul
2
o:
cc
m
Ul
o
Q
Z
FINISHED
CAMERA
Ul
m
2
St
(/) Z
< D
Q
Z
E
01 *
0) U
C3 01
o
to
Ul J
ii
in
< tn
J lu
Q. o:
-------
DRAFT
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
3-874
-------
DRAFT
CO
EH
U
D
Q
§
a.
(O
EH
W
S
W
W
3
o
•H
•a •->
0) B«r-l
O C -rl
3 •* -rl g
•a • c
O .p
3 0) .C <0
01 iH
•P ID
•H >
C
3 id
C Hi
O O
-O
IU
3 .
ID r-l TJ
k -H
•^ CM
E r^
en
ID rH
•
r- C
r~ -H
o C -P
T3 O C
-rH OJ
C -P -O
o o -H
-H 3 c
H 13 3
H o
-H ^ ra
g a-H
in
o:
U)
kl
o
>
Ul
o
o
z
p
a:
Ul
a.
o
Y.
K
04
o
(Ml
o g
in o
ui
O
O
•H
o
z
K
!x
a
H
§
CO
§
o
H
e
in
O»
•
p4
•
m
r-i
id
§
•H w
P 14
0 C
US 4J
u o
fc, £
03
V
0)
(0
u
,c
o
10
it
C
41
2
ID
0)
ID
id
o
.C
o
4.1
10
S
~
G
O
3
M
W
-p
o
T3 (0
C 0)
It) 3)
-P 0
91 S
X 0
U -P
O 10
04 S
a
o
P
« C
'•i £
RS
>
E O
M S
10
H
B)
•H
1-1
V
10
£
u
111
IJ
o
rH
iH
<
•O
0)
•o
n
o
o
-------
DRAFT
z
E
r>
H
U
<
U.
D
Z
U
o
U
CM
^r
CO
LU
DC
O
3-876
-------
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
-------
u
D
Q
O
K
ftl
DRAFT
01 18
+) IS rH
C H O
3 O Q
O IN
H
X
U
E
0) - " -H
,Q ~>
g c a
3 H
C a,
•a •
a T o
0) U >X'
C 3 0-.
H T3
'4-1 O 4-,
a) n o
T3 ^
c a:
3 01 3
C/l
E-i
ffl
<
Q
z
o
I-
u
D
Q
o
Q:
Q.
a:
I-
Q
z
111
O
0
w
a:
Q.
cB
o:
x;
><
111
a:
Ul
55
O
u
T3
11
•a
1-1
o
u
0)
4J
o
I*
z
3-880
-------
DRAFT
FINISHED
CROWN
HEMICAL
CLEAN
O
l
I
tn
2
i
FINISHED
LOOP
BEND
H
D
O
DEBURR
i
Q
8
).
ALLO
H
(fl
O
FINISHED
1
h
Ul
O
Z
E
STONE
i
I
u
)
2
Q.
SOLDER LOO
I
TO CROWN
t
4
g
h
c
<
y
2
t!
2
Q
U
(J
cr
UJ
CJ
33
-------
DRAFT
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
3-884
-------
DRAFT
z
w
cr, w
r-l -H
I
C O -
H 3 C
C 'O O
•O O O -rt
Ci H r4 rH
U rH CUrH
3 rH -H
'O -H tT> E
0 E C
U H -a-
Cur- C •
• -H T
0)
n £ r-i
In
O
H (1) EH ll> 4)
C 3 3 H
3 rH rH 1W
v^ > U) > -P
rH U C
in O O -H C
rH <4H T3 4J 3
o:
<•
Lu
_l
Z
•Si
.
W « W
c c
O CT\ O
t^ CO EH
s
O
U
M
'1J
04
(B
JJ
0)
rH (I)
H 4J
0) >i
U, O
CbrH
O rH
U <
3-885
-------
DRAFT
FINISHED
BLADE
ce
or
m
UJ
Q
i
Q
Z
£
a
FINISHED
HANDLE
UJ
H
_J
Q.
i
FORM
j 1
< i i
Q.
STAM
LU
a
EXTRU
FINISHED
i
KNIFE
X
in
2
UJ
_J
ASSEMB
\
1 i i
g £
do
(/)
-------
DRAFT
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
3-88Q
-------
DRAFT
01
EH
U
Q
O
fc,
o
2
W
CM
M
C 10
o n
•H (0
•H O
S Q
CM
CM
C en
O H
•H 10
rH ^H
I-H r-<
•rH O
2 D
CM
O
C to
O M
•rH BJ
-H O
S Q
00
in
W
3
W .H
CT>
-------
DRAFT
Q
Z
LU
CO
D
UJ
u. o
UJ
J
CD
2
LU
in
in
I
en
2
a:
o
u.
LU
I-
<
J
0.
a.
2
<
a:
LU
a
UJ O
u o
T H
-------
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
-------
urtMr i
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
-------
DRAFT
D
Q
8
W
0.
c
o
-r4
e i-t
-H r-t
-H
•O 6
CD
o n
3 •
•d 01
O 01
I
O
3
•a
o c
n o
O.-H
(U
o
0)
(-1 el
OJ 3
S -H
(0
m >
4->
-H (0
C
C-H
•H e
a "4-1
•H Cst -H
(0 iH 4-1
S •* C
0) 01
M 4-1 T3
(0 -H
3 01
w
a
01 > 01
O l
O
^3 - td •• nJ
-
•^r
CO
CO
lu
Q
2
04
Q
D
U3
O
U
U
EH
«!
2
•a
0)
•a
M
o
o
cu
4J
O
Z
3-896
-------
DRAFT
o
T i* til
in E 5
•y ^~ ^-
£ H CE
u. in u.
1
j
j
5
D
1
UJ
.-J
2)
>^'
u,
yj
in
QZ
Ul z-
I C
T n
in z o:
7 ~
j «.
£OO
u. in m
z
o
ADHES
1
2
1
Ul
o
I
in
u.
a
I
)
~z.
0
^
^Ui
in s z ~
' '-U O
X Z
Q O
f CD
S^
218
5 lL
*
a
Ul
i
en ui
^ I/)
u! u
i
111
in
i in
U F
or Q:
D <
a. Q.
Ul
m
ASSEM
,
in
Ul
o
<
U.
in
i-
D
O
1
Z
O
ADHES
BOND
_i
< in
u fc
MEGHAN
FASTEN
T
IT
Ul
U
I <
U) U.
15
u. in
D
0
f
UJ
U. 0.
Ul
z
I-
u
Ul
D.
in
z
-------
I-
in
N
I
8
LJ 7
111 JC
i 2
in z (-
— o: o
= O Ul
U. I 10
3
i in S
m > en
5 -I D
5 < O
u. > i
_
j
£
Q
_
i _l I-
!2 in o
z m in
C «
|
111
o
s|
UJ
EC
J
U.
K
0
O
z
111
CD
Uj bl
I £
in 5
ii
U. I-
u
a
in
in
in
z
cc
a:
Q
in o
2£
CD in
C3
Z
5E
o
<
LL
D
Z
f-
LU
Q.
(/) 111
< ffl
K 3
ffl H
U)
(/) Lu
in
I
in
UJ
DC
D
O
01
I/I Ul
< m
D: D
D3 I-
3-898
-------
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
0
0
0
0
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
-------
Q
M
«
DRAFT
c cr
•H C O W
0 -H H
T3 H -P
GJ r—i u en
3 H T3 10
T3 g O rH
O >H rH
>H T a o
a • TS
1) co C C
•H rH H O
^ c: H
3 UH H -H
O O M
u] £ H
-P HI 0) c
•H 3 IH
C r-H r-
O (B X! in -3
O £-t C"i di
O C3 H
i—i p n |
* ^4 • fO H
O O W J-1
(H (Tj 3
in
E-i
•Z
U)
H
CQ
o
t-
u
Q
a:
1-
D
Z
O
Q
kj
a:
ra
C
O
EH
co in
co o
^
Z
m
Q
o
u
til
H
14}
(U
O.
J^
CO
rH
r-\
H
a
in
o
•H
U)
<0
(H
a
g
t.
o
s
•d
o
ffl
M 01
ifl M
0 V
ca c
-H
M 10
(1) 4J
ac
(8 O
ft U
d.
t
BG
r— 1
(C
C
O
rH
-IJ
O
ID
i-i
In
t/j
^
O
4J
O
f-
•O
(U
T)
Vl
O
O
01
o
Z
1-901
-------
DRAFT
o
111
I
0)
ui o z
< D <
Q
111
I P
(/) -I i
= _l 5
= OO
It Q 0
I/)
Ul
O
5 o j
IL Q (J
Ul
in
i;
(A 2
ec.
Ul
3 O
O I-
z
o:
D
U
<
U.
D
Z
J
_J
O
Q
ro
in
tu
o:
o
0.
8
is
Ul (A
X Ul
o
It
ID
U.
3-902
-------
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
U)
e-l
U
;_>
a
§
a.
tn
o
E-
Z
tn
O
C C 4J
c o o c
rl -H -rl 5)
•-I 4J TJ
T3 rH O -H
W -H 3 C
o i; -a 3
•J o
"J CM H J-.
o • a-H
n r-
Q« UH
Q
g
i-
u
D
O
O
a:
Q.
D
Q
Z
LJ
_l
y
i
lu
Z
LU
a:
Q
.J
I
U
O
Q
w
2
O
O
tl
U
o
-H
4J
tn
fU
r-i
a
o
G
^i
a)
x;
EH
0
0) ^H
O ~-
• H
H
XI
id
fn
c
d)
>
0
3
•a
10
o
n
a
T3
M
03
0
n
iH
0)
a
ra
n
Ul
M
(1)
C
•H
id
jj
c
o
u
cu
-—1
rH
It
C
o
•H ra
•P M
u o
10 4->
^ o
fe S
tfl
rH
Ifl
H
^J
HI
JJ
fO
s
^4
(U
J3
4-)
o
rH
-H
<
o
-o
^
o
o
0)
o
2
O
§1
^H
UD
CO
O>
^H
0
rsj
0
CM
i-H
01
C
O
EH
o
O
LO
*•
Csl
n
^H
"^
,4
CN
rO
CTi
O
r-J
(N
CT»
1/1
r-t
on
c
o
H
0
o
m
»
LO
r*-
pH
* — '
n
01
J-)
(D
2
0
•^
\D
CN
a»
U3
a>
U)
T3
>1
C
rl
J
c
o
-H
rH
-H
a
o
^
n
< in
\ 0
2
VO
ro
<
\
2
tu
o:
3-906
-------
DRAFT
LU l/i
7- lit
!- ft
-------
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
-------
DRAFT
O O I
O rH U 3
O -H 3
3 B "J M
6 UO £
00 3V O
-H
O - I
1/1
H
2
<
a
z
O
H
U
cc
I-
in
D
a
z
Q
0
8
y
LU
_J
I
Z
H-
O
Q.
(NO (71 O
- O
O
o
o
UJ
EC
* in
CO CO
ID rH
(U
JJ
3
C
•H >i
s o
3 M
a,
o
^
0)
O
•d
n)
o
l-l
a)
.c
4J
03
OJ
in
0)
X
0 CM
X
0)
O,
ra
a.
c
o
H (0
-P i-l
O O
a 4J
v< o
-p
o
0)
TD
Vj
O
U
0)
3-912
-------
DRAFT
FINISHED
WALL
SECTIONS
1-
z
~~
0.
z
LI
J
u
£
Z
<
m
FINISHED
BRACES AND
FRAME
Z
^
a.
z
^
LU
_j
o
Q
Z
§
't-
FINISHED
PLASTIC
LINFR
LJ
D
J
O
in 2 -i
U. (/? 0.
LJ
J
CO
LJ
in z t
< o in
H
D
U
a:
Q
z
111
J
u
• "T
fL
STAM
i
I
U
Z
a.
1
cc.
UJ
I
l/l
WELD
h
D
U
U
1- X
in o
< o
D- in
-
T
*UJ^
UJ _l U
moo
D Z H-
i- < in
t- -> X
UJ < U
Ui H o
-------
DRAFT
^-
D
u
]
2
Q
'
I- <
< U
I 1-
1
RINSE
i
UI
J
O
CL
t
STEEL
TUBING
'
ti
I t-
tn u.
5 <
i I
b. in
j
-7
<
u
j
u
1
111
1-
<
J
Q.
CLEAN
1
o:
LU
n
2
UJ
1-
'
?<°
^2
c2
1
<
LJ
J
o
UJ
<
0.
'
HEAT
TREAT
j
_l
£
Q
MACHINE
1
O 1-
K Q; I/)
o o <
U- 0
o
g
2>!5§
^8d
i
h ...
£*12
« h
j
in
_i
2
j
LJ
O
<
i
Q.
S
O
Q
Q
<
'
SSEMBLE
1
_§i
g§
<
11 li
< m UJ O
x H I m
0 (/) 0
5 L.
D
H
O
<
LJL
D
Z
m
D
J
O
u.
8
oo
in
CO
I
ro
U
QL
(D
3-914
-------
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.
-------
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
-------
D
Z
DRAFT
t.
o
-
0) O
; 13
tfl 3 ^
4-> 13 TJ
•H rH 0)
C > • -J '
O
O ^
O O
U) rH O
^ rO H
f3 > tw
|—t H
r-l - -U
^ CN C -P H
-r- o O C
r- ON H a p
i1 ^H o in
- c -H M IB
n H g a- '£
§
w
in
O
u
01
•O
K
±>
O
-------
DRAFT
D -1
UJ CD
in uj
5 t (j)
U. H <
2
OH
o
LL
j
SHEAR
EXTRUDE
BRASS
STOCK
4ISHED
C TUBE
E *
<>
ce
LU
in
i >
EXTRUDE
I
ERMOPLASTIC
SIN
I LU
i- a:
Q
UJ
in
z z
il Q.
i
0-
t_. lit ^
CO U
5 H S
m 0
S * uj
p z i
j i- I
c 5 "•
'
1 1 1
1 LL|
1 1 1 - 1 1
in "~ o m
in H
o
i-
(X
0
a:
LU
X
H
Ul
in
o
MOLD
1
Z
in
UJ
cc
(3
Z
U
<
U.
z
z
LU
Q.
H
Z
O
Q.
J
<
DQ
o
to
00
CO
U
DC
O
U.
-------
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
-------
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
-------
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
-------
in
M
yi nj in
4J rH
•H £, M
C 4-1 O
3 -H >O
DRAFT
10
E*
Z
w
s
O
a
O M 0 u-t
(U M O
T3 a
C (U
3 o 3
l< -H
c M
lu
U)
O
U
Lu
o:
a.
a.
LU
u
X
LU
in"
Lu
i-
LU
O
u z
o
go
> tt
LU £
H "
in §
>H
a
LU
a:
D
en
z
o
u
Ul
,-1
-------
DRAFT
,£H
Q D.
^8
z
o
u
Q
S!z
(fl ?
7 O
2 a:
u. o
8
a:
a:
m
UJ
a
H
tfl
<
O
UJ < I-
(/) 1- -J
< Ul UJ
m 2 S
Q
UJ
O
U. _l
UJ
ffi
I-
Z)
U
_J
UJ <
5t
m 5
D y
LJ 5
X Z)
U) H u
7^7
So?
u. o o:
i
to
j
UJ
in
UJ
<
a.
Lu UJ
i _i
O U
-------
DRAFT
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.
-------
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
-------
DRAFT
u
o
a
s
(X
lu
O
B C
•H O
•H
•O r-4
« •-!
0-H 3 C
3 e-d o
O Cn 14 r-l
o> t?> e
(U -H C
» -^t <»
OI«M C
a
£
(u
O
W
O
cm
3 >
*>
a •
-a
-a «i
4) -H
3m
o «
o
f> M tH -H
» O • « *•
a> "w in > C
rH U ID
n - nj -'O
- 01 rH C -H
T r~ iH O
O> CT> O -H M
TT rH >O 4J -H
H
13
9
EH
to
a
g
i-
o
a
a:
in
D
D
Z
kl
I
in
a:
m
in
I
a
m
J,
lu
a:
Q
a
M
X
Q
I
W
§
<
z
•a
-------
DRAFT
(D
LU
§£
s
m
O
FORM
LU
£L
I
in
TE WITH
ROSION
ST
PLA
COR
RES
D
LU
I I
(f) en
5 D
± QL
U. CQ
LU
_J
CO O LU
2 I- J
LU LU Q
in | <
< 3: I
LU
^
DC Z
O <
LL I
2 LU
W) LU (/)
I- £ CQ
O
2
u
h
(/)
QC ±
LU in
I LU
I- C
3-927
-------
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.
-------
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
-------
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
-------
DRAFT
u
Q
O
4-> M
4H -rH rj
O 3 ^H
rH
IH rM O
<1) r~ T3
XI 01
e -H =
3 O
C C H
Cu
o
0) rO H
•H C) S
14-1 O
4-1 3 CN
C -0 •
-------
DRAFT
FINISHED
DISPLAY
RACK
BRIGHT
SPOT
PLATE
0.
a
WELD
FORM
Q
z
LU
m
i
I-
D
U
4
u'
LU
a:
(5
1=.
E
D
H
U
<
Lu
D
Z
U
<
a:
a.
in
5
LU
a:
(£>
10
CO
I
CO
LU
a:
Q
O
o:
3-932
-------
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.
-------
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
-------
DRAFT
c
0
C -H
-H O
-i 3
g "O C
n M X
• a .--i
0
S-i r\i
2
E
tnl
O
5) 3
C .C 13
3 10 H (U W
3 H
O iH rH
o o • ra -
m 14-1 (A > w
* 03 - ro
O
U1 r
rH O t— I
\ O -H O
t3 -P t)
Z
O
(J
a
o
ct
n
o:
Q
Z
in
H
iu
X
(1)
<
U
a
m
Q
2
ct
o
a
a
s
I
o
u
•o
CJ
T)
^
0
o
01
o
2
-------
ui o
H r^
y
a.
Q
E
o
UJ
g
FORM
STAMP
i- -J
u/ <
LU I"
"r LU
yi 2
SH
I UJ
Ifl *
- Ul
il o
u I-
UJ 1/1
Q- UJ
in t-
'Z- ,*
u.
g
SE
•z. \-
u
CD
5 j, a
UJ * UJ
in x >
in o o
< m o
DRAFT
y
a: .
• m o
< H
u. u
Is
o J
^ <
5 U.
>
x
Si
UI Q
PAINT
o
z
E
^
f-
u
<
li.
D
Z
<
2
(/)
f-
u
:*:
-------
U.S. ENVIRONMENTAL PROTECTION AGENCY (A-107)
WASHINGTON, D.C. 20460
POSTAGE AND FEES PAID
ENVIRONMENTAL PROTECTION AGENCY
EPA-335
-------