Monday, December 21, 2015

Cast Iron and Mayonnaise


As I drove my shovel across the concrete floor and into the pile of oily metal shavings, I could hear it echo through the plant. It was quiet for the first time in a week and it was also the first time I had a real sense of what we were doing.

Little more than a week earlier, as I once again found myself out of work, I called the temp agency to see if they had a new assignment that would fit my rather eccentric skill set. To my surprise, they had something they described as an “auction helper.” Great! I had organized several auctions and so I accepted the gig that started the very next morning.

Getting an assignment before the holidays was huge and having a paycheck before Christmas was even bigger.

So, the next morning, armed with no other information than a job title, I showed up to the site in my khakis, open-necked dress shirt, sweater and a notebook.

I should have known better.

The job site was a now-shuttered manufacturing plant on the edge of town. According to the For Sale sign, it was three-quarters of a million square feet. According to some of the plant's former employees that I would later meet, the plant used to make axles for military and civilian vehicles.

It had been a heavy industry that employed generations of people over its sixty-seven year run. These were the jobs that allowed people to build a life for themselves and their families. These were the jobs our grandparents had and that our parents and other political leaders believe are still out there. These were forty-hour-two-weeks-vacation jobs that led people into the middle class. And they made that journey by the sweat of their brow and the skill of their hands.

Like the great medieval churches with stone steps transformed into abstract shapes worthy of Henry Moore, signs of the plant's heavy use were everywhere: painted steel railings worn raw, doorknobs polished bright by hundreds and thousands of hands, grease-stained lockers and everywhere the evidence of time passing as dust, metal and new technologies accumulated layers in a cake.

The plant had closed for the last time about two months earlier. The company had moved out the machinery and the people they wanted and now hired a contractor to sell off the rest.

The day I started was the preview for the auction. It was an opportunity for prospective buyers to look at the items and decide what they were willing to spend.

It was also a chance for me to explore the building and soak in its history.

That first day, I was assigned to work security. It was my job to patrol a section of the plant and make sure the customers weren't adding, or subtracting, items from any of the defined lots.

It was pretty light duty for the most part given that many of the lots were heavy machine tools that would require forklifts to pry from the shop floor.

The lots were being sold as-is-where-is which, in most cases meant contents included. In my area that meant cabinets and shelving full of bits and tooling used in those heavy machines.

And when I say “bits” you might be tempted to think in terms of the cracked plastic drill index you inherited from your father, or the bits that came with the router your in-laws gave you for Christmas, but you would be mistaken. The bits I am talking about were the size of a football and weighed about as much as the average third-grader.

My bosses with the auction seemed convinced these items would be in high demand and made certain I paid close attention to them. So, for eleven hours, I walked my post in the southeast quadrant and was interrupted only occasionally by potential buyers.

I herd many more buyers than I saw—sound now carried freely through the plant. It rushed to fill the space left by the missing employees and the relocated machines.

Every once in a while, my pacing was interrupted by a passing electric cart. Security, plant staff and my bosses would each make passes to check up on me and make certain no one was trying to steal the building.

At the beginning of the day, I was overly optimistic. I thought I was an overweight guy in need of some exercise so I will embrace this opportunity to walk and thus draw down my reserve of spare calories. By the time I was working on my second layer of blisters I began to actively consider what it would take to highjack one of those cards. It was a big plant, how quickly would they find the body, really?

My beat covered six distinct “neighborhoods.” There was a testing area next to the loading dock to verify that materials received were up to spec, the room for tooling, a machine show, a sharpening area and two different areas for machining parts.

The quality control area was set-off from the plant as a sort of building-within-a-building. The equipment in this area was all white and looked barely used. If it were a jewelry store, you would know just by looking in the window that you would never be able to afford anything inside.

The tooling room had a living history museum quality to it in that it was full of all manner of unusual things that you wanted to know how they were used.

The sharpening room was another building-in-building, but instead of looking like a jewelry store, it had a quality like those settings they make at Disneyworld that look like you just missed whoever it was who worked there. The room looked like a roadside garage from a time before the interstate highway system.

The machine shop was tucked away in a corner at the intersection of two firewalls. It was dark and well away from the skylights that seemed to be in every other part of the building. The drab cement walls and concrete floors were the same oily black color and, if you strayed from the beaten path you could hear the crunching sound of metal shavings under your foot.

The machines in this area were all painted a kind of blue-green that you might only see in the gyms of older schools and municipal swimming pools. These were unquestionably durable tools made from massive shapes formed in molten cast iron. Sheet metal—the mayonnaise of our modern age—was used sparingly to house switches and enclose massive copper fuses.

But more than anything else, more than the massive scale, functional design or uniform color, what you noticed about this equipment were the wheels, knobs and levers used to control them. You noticed them because they were shiny and they were shiny because of the decades of polishing they received at the hands of their operators.

Perhaps I should explain, for those of you who haven't been to a science museum, that axle are more complex than just a piece of pipe and some bearings. In order for cars to turn properly, the wheels on either side of the vehicle have to turn at different rates. When you turn left, your back right tires have to travel a lot farther than the left. They are powered from a single engine turning at a constant rate, but the wheels, periodically have to travel at different speeds. To be able to do this and also rotate both tires at the same speed when traveling in a straight line requires gears, lots of gears and cutting those gears was the job of much of the plant's equipment.

Imagine for a moment all the steps that might be involved in making a gear from a piece of solid steel. And, while you're thinking about that, remember that where there is one gear there is at least one other and the teeth on your gear have to mesh perfectly with the teeth on that other gear that's being made by somebody else.

To even begin to get that right means that regardless of what happened before it got to you, the piece of steel, the “blank” has to be the exact size and shape of the one you made ten minutes, ten weeks or even ten years ago. And I mean it has to MATCH, or it gets expensive very quickly.

Now imagine making that gear by hand without a computer or a 3D printer or any of a thousand other modern crutches. All you have to work with is your hands, a drawing and a few measuring tools.

To do that work and do it well is a skill and one that is not learned from a book or by watching a video: it is the product—like most other things of value—of experience.

These machines in this dark corner of an idled plant showed their experience and seemed ready, at a moment's notice to go again, ready to get back to work. They were like the pets you see at the animal shelter: scarred but hopeful.

Right next door was the machining area with more modern equipment. These machines were much less interesting, much less poetic. No longer needed were the hands of experience, they were replaced by the anonymity of ones and zeroes and the inevitability of computers. No longer was uniformity a goal to be measured against, but it was an expectation and anything less was an aberration, a reject, a discard.

Very little cast iron in this room; lots of mayonnaise.

The other thing I noticed about the equipment in this room is that there was nothing shiny. You can still see the evidence of human operators as in the machine shop, but instead of well-worn controls polished bright by frequent use, you see oily fingerprints on the screens and keyboards.

Not for nothing, but this was also the only one of the rooms where oil was collecting on the floor, having leaked from one or more of the machines like the slime trail left by a slug as it squirms across your porch.

The end point of my circuit was the heat-treating area where pieces and parts were delivered into the maw of a garage-sized furnace designed to harden the steel and strengthen the finished product.
The furnace was a gruesome assemblage of ovens, piping, valves and gauges It put me in mind of the massive coal-fired blast furnaces that gave birth to the industrial age, and of other ovens that gave birth to a less innocent, more destructive age.

Birth and death.

Past and future.

Round and round I went protecting the past, presiding over its dissection and lamenting the loss of another tradition.

Lap after lap.

Less you should think me some kind of hypocrite, I will freely admit that progress is great, that technology is cool, but, for every iPhone and Tesla, there is a displaced worker left wondering what happened to the bargain made with their employer.

The employees sold their time in exchange for a promise that they would e secure in their retirement. They worked with the chemicals, they risked their health so that they could look forward to a brighter day free from worry. But, when the going got tough, the employers got going and with them went the employee pensions and their access to healthcare.

This is not a new story. It is one that has probably been repeated more than once since I began this sentence. But it's one thing to read a headline about a plant closure and quite another to look at the silent machines and tables full of tools that are out of work.

I don't mean to draw equivalence, but there is no denying a solemnity comparable to the piles of shoes that no longer have feet to protect, or footsteps to follow.

On the day of the auction, I met a number of former employees who were taking one last turn through the plant that had been a center for so much of their lives.

One woman wanted to have her picture taken in front of a giant machine because, as she said, her kids would never believe that she had run it.

There is a program I like to watch on the Science Channel called “How It's Made.” The producers sent their camera crews to factories and workshops all over the world and document the fabrication of everything from electric violins to headlight reflectors. It's a terrific program to watch and zone out to: lots of motion, very little dialogue, not much to think about. A frequent topic are the various forms of packaged foods. It can be fascinating to see the choreography of complex machinery as the product moves from ingredients to packaged piece with only nominal human intervention. Where you do see human hands they are loading the machines, or transferring product from one automated line to another.

We demand lower prices and higher efficiencies, which drives automation in and people out: this is the bright future we have set for ourselves.

What good is a bright future if you can't afford to live there?

During the week that I worked with the auction company one question came up time and again from the high bidders: what was going to happen to the building?

As far as I was able to determine, there is no plan. For one thing, it's really not suited to much other than the purpose for which it was built; and for another, who would want three-quarters of a million square feet for anything except maybe a warehouse space that would be packed by machine with goods made by other machines.

So, there I was, day after the final gavel fell, sweeping out the corners of this cathedral of work listening to every shovel hit the trash can, every stroke of the broom as it bounced off every wall. Many of the bidders have come and gone with their spoils. What's left are the discarded gloves, the partially emptied lockers and an uncertain future.

Perhaps I am more than a little sensitive to uncertain futures and the promise of work.

It's been three years since I last had a traditional full-time job and, with each passing day, I feel more like Tiny Tim with his face pressed against the window of that toy store.

Being unemployed, or even underemployed, is a lot like that oily shop floor: it doesn't take much to put you on your back.

When I was working full-time, it was easy to be cynical about the ideas of hard work and merit. These were held up as the keys to advancement, to leveling-up even as Mary-Catherine, who started after you got an office with a window and you got written up for coming in late that one time. I always thought there would be other turns, another hand when the cards would come my way.

Standing on the snowy side of that window, things look a lot different. Work is more like a privilege: something you got to do instead of had to do.

I noticed that in the assignments I have had since being a temp worker, I have resisted stopping work, having to take breaks, or even lunch. Perhaps it was for fear of not measuring up in some way, but, most likely, it was because I had a very clear sense of how ephemeral a job can be.

I get that times have changed and that global competition requires a nimble economy and an even more nimble workforce, but work is a contract where each side benefits.

For the last generation, the benefits have been something other than mutual and much less than equitable. Somehow, it has become acceptable to move away from thinking of labor as a partner in corporate success to being now seen as a millstone around the company's neck

I wouldn't have a job without this shift in mindset, but I also know that I don't have much of a future.

Like the items up for auction, I am wearing my own identification tag, hoping that someone will see the value, bid on me and put me back to work.

Dark thought indeed for a holiday season, but not entirely out of keeping with the season.

Even as the snow stubbornly, miserly, refuses to fall, darkness crowds in, if only to provide stark contrast for the inflatable Homer Simpsons and the cartoon Minions.
Stark contrasts are what this time of year is all about: barren trees festooned with colorful lights, fist fights among adults over toys that will bring the most joy, celebratory feasts in the midst of so much poverty and hunger.

These are among the many threads that continue to bind us to Dickens Christmas story of so long ago. Progress was also rampant in mid-nineteenth century Britain enriching many good men of business while sending many more to the prisons and the workhouses. Scrooge is the poster child for this modern times and he, quite literally, has to be scared into changing his outlook, to start making mankind his business.

It surprised me to find, as I made my laps around this soon-to-be-abandoned cathedral, that it was not Scrooge that I was thinking about, but Old Mr. Fezziwig, his first employer.

Fezziwig's business also closed, but not because he chose to move it to a place where labor was cheaper, but because he didn't. By today's metrics that would make Fezziwig a loser, a bad business man. And perhaps he was, if dollars and cents are the only yardstick. They were clearly not his yardstick. He honored his responsibility to the people and the families who worked for him.

As I passed the giant ovens I couldn't help but wonder what it would take to scare our modern-day scrooges into a new perspective and different priorities.

I should have perhaps added pages ago that I really do like the holidays but, as they seem to keep coming around faster and faster each year, it seems important to look beyond the Chia pets and the larger flat-screen and remember that not everyone gets a turn, or rolls double-sixes. Like the machines, the tools and their displaced operators, everyone deserves a second chance.

Happy Christmas.

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