For an American watching this, it's like going back 100 years in time, when human life was cheaper than machinery. I have a lot of compassion for men who must work in these conditions to feed their family.
I'm so glad that the antiquated, open geared, open pinch point junk we made in the 30's and scrapped in the early 70's to keep our insurance costs low, got a new home.
Yeah its stuff from the 20s and 30s. I ran a highfreq tube mill almost 25 years and it was from the 70s. It was updated, but the weld current came from a radio oscillator tube. Today it's all mosfets transistors that creates the highfreq current
@@FjHenderson Newcastle NSW Tubemakers Duragal mill 1994-2010, added inline gal tank and internal painting lances after inspection bench, was operator and later maintenance then off to Uni after that! It was a 2 inch mill, so 20*20 up 100*100 in the middle 50*50 at 100 metres per minute. yellow guards everywhere and a complete concrete jungle complete with a row of Gantry cranes that would be most costly, it was originally built after 1950 but tat mill had been up graded so many times it was completely different when I was there, I know it it still running
@@StevenHaze Sorry, been side-tracked. I am from Ohio in the USA, a short drive from Cleveland, and Pittsburgh. Before everything was made of plastic, round and square tubing was made to make handles - in my case for sweeper handles. (Hoover) Even in 1970, we were 30 years ahead of this. We did take flat stock from rolls, pull it thru forming rollers, into a round tube and weld the seam. a lot of the equipment had a dark dingy look like this, but through the noise and sound, made a nice part.
@@miketrissel5494 Its all good my friend, we all have lives to attend to!! At the beginning we lifted coils in vertically to a hopper that held 4-5 coils and had a mechanical join welder, then after that a rotating disk table (called accumulator). so the coil would unwind faster than the mill and get enough lead to weld the next one on. Then it passed though a shot blaster that was a 24 feet high 60 foot long 30-40 foot wide steel shot blaster that removed millscale, rust etc (maintenance was heavy work on that over continuous Saturday overtime shifts!). After seam welding it had additional acid, pickling tanks and a pumped coat tank of liquid zinc. This is then air dyed off to create the smoothest gal coating you have ever seen. Then 30 (90 feet) metres of water cooling before shaping round or square. Same plant had a gal dipped as well and in typical Australian fashion we called it the "galvo" department! www.infrabuild.com/products/duragal/
give the welding section some goggles. perhaps even fabricated from old CD's or something. Can't imagine having to work like that knowing if you get sick or injured it's probably game over... The process itself and the filming is outstanding imho.
One of the best production clips I have ever seen. No annoying talking or music just machinery sounds and clear footage of the process and don't worry the steel is stronger than the low carbon rubbish from Chyynna. Well done guys.
Glad to see the blind guy getting a job in where-ever-stan, helping the disabled is commendable. Also, I'd like to say "Noice one!" to three toed Trevor for try to move half a tone of steel by shoving it with his foot, top stuff.
It was Kool as hell to see how we used to do it in 1930, I am amazed that these people can do such work in these conditions. I mean they get it done & you know it's cheap. No guards on the running belts or the pulleys, one slip & it's an arm or worse, puff! With all the crap cluttering up the place, you wonder how many accidents happen?
This shop makes a product that sells. The cost of PPE is peanuts. The difference is the owners are not compelled by law to provide PPE and a safe workplace, so they don’t.
@@LeggaTim I'm absolutely not opposed to buying American if you can afford it. The ideal amount of safety though, is somewhere between those two extremes.
Lower energy costs start the ball rolling. India has subsidised, Coal fired, energy for a lot of manufacturing and excellent grants for renewables if used for production. A place a I was working at least year had all of the power requirements for one foundry and machine shop provided by a large Solar array on the roof. With lots of sunshine and regular cleaning (India is dusty) it works well. They run a five day, three shift system and export power on the down days. Quality wise they were good, the plant I was based at manufacturers all of the engine cylinder liners for Jaguar/Landrover. Labour costs don't play that big a part as the foundry and machine shops were highly automated.
I guess they didn't wish to show any of their QC or SPC activities. Or any PPE. I'm a Mechanical Engineer and an Industrial Hygienist and *_BOTH_* of them are freakin' out.
Beautifull machinery, Its gets the job done."Boy, those open gearworks are frightening and those workers with those long loose clothing"?I dont even want to think of, Even if tou look there is not even a MASTER KILL SWITCH TO STOP THE MACHINE?
How many work-related fatalities did this factory have this week? Lost limbs? Crushed fingers? Falls? Damaged eyesight? Half the safety violations could be fixed within an hour if someone gave a damn. The other half could be fixed in a week with a little training and effort.
I just looked up, Pakistan is only second to India in fatal workplace accidents, 44.2 deaths per 100,000. India has 116, the U.S. has 5.2. The average laborer in Pakistan makes $9.50 for a 12 hour day.
@@bigredc222 I've seen similar dangerous facilities in South East Asia. No one really seemed to care despite many issues being a trivial thing to fix. I believe a lot of it is a cultural fatalism. I've also been to factories in Indonesia where Western client companies demand proper safety equipment and processes. Worker safety, satisfaction and output is significantly higher in factories with enforced safe work practices. Client companies also pay for some safety iniatives and have inspectors to make sure safety is observed. If purchasing companies demanded such basics of their Pakistani and Indian suppliers before agreeing to buy from these factories, the worst of these issues would be fixed quick smart.
Roll forming of the steel is a form of forging, which is a manufacturing process involving the shaping of metal using localized compressive forces. That roll looks like crap and you may suspect integrity of anything produced by it.
I don't think I've ever seen somebody weld before with NO face or eye protection. Why do most of these "how it's made" videos take place in third world countries where human life and health is next to worthless?
Because most people in developed countries demand it. Let's face it.....probably 90% of items in our homes come from under developed countries. It's all about how much we are prepared to pay
Check out the other comments about old work environments. Modern safety mandates were developed over many years as a result of accidents in factories in the UK, France, Germany and the US and other countries. It's been a long process and countries without the mandates or means financially do what they need to do for now.
@@user-vp1sc7tt4m My comment was meant more for how someone set up a company then let it grind itself down into the dirt. Most of these videos show a brick floor, at least a solid floor, but they show no signs of having ever been swept. scrap is scattered around. Care of the workplace cost very little to no money. The machinery is just this side of junk and there is nearly no care for the workers safety. This does cost but requires some foresight. I had a machinery book dating from the 1910s that mentioned worker safety if for no other reason. because it cost the employer to replace an injured worker.
Depends on the type of steel used. The heat of the processes drives off most of the water, but once cooled and with enough exposure, rust might begin to take hold on the finished tubes.
Structural steel like this, that is prone to rust, is usually shipped to the customer with a light film of grease/lubricant on the outside which mitigates rust. All of that is cleaned off with solvents prior to priming and painting or powder coating.
With all the garbage and debris scattered around it's clear the employees do not take pride in their work. Would not trust the quality of the end product.
For an American watching this, it's like going back 100 years in time, when human life was cheaper than machinery. I have a lot of compassion for men who must work in these conditions to feed their family.
I'm so glad that the antiquated, open geared, open pinch point junk we made in the 30's and scrapped in the early 70's to keep our insurance costs low, got a new home.
Where are you in the World? I am in Australia and thought pretty much the same thing! not to mention the inspection bench was a knee killer!
Yeah its stuff from the 20s and 30s. I ran a highfreq tube mill almost 25 years and it was from the 70s. It was updated, but the weld current came from a radio oscillator tube. Today it's all mosfets transistors that creates the highfreq current
@@FjHenderson Newcastle NSW Tubemakers Duragal mill 1994-2010, added inline gal tank and internal painting lances after inspection bench, was operator and later maintenance then off to Uni after that! It was a 2 inch mill, so 20*20 up 100*100 in the middle 50*50 at 100 metres per minute. yellow guards everywhere and a complete concrete jungle complete with a row of Gantry cranes that would be most costly, it was originally built after 1950 but tat mill had been up graded so many times it was completely different when I was there, I know it it still running
@@StevenHaze Sorry, been side-tracked. I am from Ohio in the USA, a short drive from Cleveland, and Pittsburgh. Before everything was made of plastic, round and square tubing was made to make handles - in my case for sweeper handles. (Hoover) Even in 1970, we were 30 years ahead of this. We did take flat stock from rolls, pull it thru forming rollers, into a round tube and weld the seam. a lot of the equipment had a dark dingy look like this, but through the noise and sound, made a nice part.
@@miketrissel5494 Its all good my friend, we all have lives to attend to!!
At the beginning we lifted coils in vertically to a hopper that held 4-5 coils and had a mechanical join welder, then after that a rotating disk table (called accumulator). so the coil would unwind faster than the mill and get enough lead to weld the next one on. Then it passed though a shot blaster that was a 24 feet high 60 foot long 30-40 foot wide steel shot blaster that removed millscale, rust etc (maintenance was heavy work on that over continuous Saturday overtime shifts!). After seam welding it had additional acid, pickling tanks and a pumped coat tank of liquid zinc. This is then air dyed off to create the smoothest gal coating you have ever seen. Then 30 (90 feet) metres of water cooling before shaping round or square. Same plant had a gal dipped as well and in typical Australian fashion we called it the "galvo" department!
www.infrabuild.com/products/duragal/
The welder's eyes may not last long. I wish him the best.
give the welding section some goggles. perhaps even fabricated from old CD's or something.
Can't imagine having to work like that knowing if you get sick or injured it's probably game over...
The process itself and the filming is outstanding imho.
Good that they have shoes. On some of the videos they work either barefoot or in flipflops
Top use of safety squints for the welding!
One of the best production clips I have ever seen. No annoying talking or music just machinery sounds and clear footage of the process and don't worry the steel is stronger than the low carbon rubbish from Chyynna. Well done guys.
Just a sneaking suspicion based on a hunch that the product coming out of this place might not be of the absolute highest quality. Just guessing here.
Glad to see the blind guy getting a job in where-ever-stan, helping the disabled is commendable. Also, I'd like to say "Noice one!" to three toed Trevor for try to move half a tone of steel by shoving it with his foot, top stuff.
Not safe, but nice to be able to see all the steps in the shaping process.
Every one of these facilities always looks like a junkyard.
No safety regulations. I love how they are working with sheet metal and wearing sandles.😮😂
It was Kool as hell to see how we used to do it in 1930, I am amazed that these people can do such work in these conditions. I mean they get it done & you know it's cheap. No guards on the running belts or the pulleys, one slip & it's an arm or worse, puff! With all the crap cluttering up the place, you wonder how many accidents happen?
Nothing like Welding with your bare eyes.... thats a Real Man right there !
Bring your own PPE. This looks like one of those Safety Training videos. “First, let’s look at how NOT to do it . . .”
This is somewhere in Pakistan or Afghanistan. There is no money for safety standards like in Europe or the U.S..
This shop makes a product that sells. The cost of PPE is peanuts. The difference is the owners are not compelled by law to provide PPE and a safe workplace, so they don’t.
@@tonyfield2360
That's right, and they pass that savings on to the entire world.
@@joshuakarr-BibleManI’d gladly pay an extra cent for my car so that that guy doesn’t go blind in a few years
@@LeggaTim
I'm absolutely not opposed to buying American if you can afford it.
The ideal amount of safety though, is somewhere between those two extremes.
Please, do a factory visit at ASML next time.
And then we wonder how they manage to make it cheaper than us in the West...
Lower energy costs start the ball rolling. India has subsidised, Coal fired, energy for a lot of manufacturing and excellent grants for renewables if used for production. A place a I was working at least year had all of the power requirements for one foundry and machine shop provided by a large Solar array on the roof. With lots of sunshine and regular cleaning (India is dusty) it works well. They run a five day, three shift system and export power on the down days.
Quality wise they were good, the plant I was based at manufacturers all of the engine cylinder liners for Jaguar/Landrover. Labour costs don't play that big a part as the foundry and machine shops were highly automated.
Great video, I can actually smell this place
Please give that guy a welding hood.
I was like….”thats round pipe!” Then the magic turned into square box section!!😵💫😵💫🍺💪💪👍
These guys are not your average Pakistanis. They have gloves.
This is the highly efficient and modern Paper Clip factory
I liked this video! Thank you!
Welder has a blind future.
Good HARD working FOLKS! AMEN!!
I guess they didn't wish to show any of their QC or SPC activities. Or any PPE. I'm a Mechanical Engineer and an Industrial Hygienist and *_BOTH_* of them are freakin' out.
Beautifull machinery, Its gets the job done."Boy, those open gearworks are frightening and those workers with those long loose clothing"?I dont even want to think of, Even if tou look there is not even a MASTER KILL SWITCH TO STOP THE MACHINE?
I know eye contacts are helpful, but I did not know welding contacts were a thing
How many work-related fatalities did this factory have this week? Lost limbs? Crushed fingers? Falls? Damaged eyesight?
Half the safety violations could be fixed within an hour if someone gave a damn. The other half could be fixed in a week with a little training and effort.
I just looked up, Pakistan is only second to India in fatal workplace accidents, 44.2 deaths per 100,000. India has 116, the U.S. has 5.2.
The average laborer in Pakistan makes $9.50 for a 12 hour day.
@@bigredc222 I've seen similar dangerous facilities in South East Asia. No one really seemed to care despite many issues being a trivial thing to fix. I believe a lot of it is a cultural fatalism.
I've also been to factories in Indonesia where Western client companies demand proper safety equipment and processes. Worker safety, satisfaction and output is significantly higher in factories with enforced safe work practices. Client companies also pay for some safety iniatives and have inspectors to make sure safety is observed.
If purchasing companies demanded such basics of their Pakistani and Indian suppliers before agreeing to buy from these factories, the worst of these issues would be fixed quick smart.
No su h thing as square pipe, pipes are round section, square means it box section.
Skip to the 8 min. mark, you won't miss anything!
Bad steel, poorly forged, with marks from poor cooking
Isn't that what we want? Cheap stuff? Big companies make more money? Shareholders happy?
@@rcpattaya230 We love cheap stuff ...Ship it !
There is no forging involved in any of these processes.
Where is the forging in this video?
Roll forming of the steel is a form of forging, which is a manufacturing process involving the shaping of metal using localized compressive forces.
That roll looks like crap and you may suspect integrity of anything produced by it.
Alguém sabe dizer onde são localizadas estas fábricas ?
The channel’s location is given as Pakistan.
Ah ok, it was bring your ''loafers'' for work day, that make more sense now.....OSHA would have a field day over there
Anyone know how the seam is welded? It looked hot and molten, but how did they do that?
Electric welding rollers under pressure.
I wondered that too! I didn't see any kind of welding equipment.
Also do you think the welder knows better? If not, you would think someone would tell him about welding safety!
I don't think I've ever seen somebody weld before with NO face or eye protection. Why do most of these "how it's made" videos take place in third world countries where human life and health is next to worthless?
Because most people in developed countries demand it. Let's face it.....probably 90% of items in our homes come from under developed countries. It's all about how much we are prepared to pay
If it’s round it’s pipe! If it’s square it’s tubing! How do they grease the open gears? Human bodies? The first thing of safety is NO loose clothing.
Incorrect. Pipe may have any profile.
How did they ever manage to set up the factory in the first place? So little care for the building, machine and people.
Check out the other comments about old work environments. Modern safety mandates were developed over many years as a result of accidents in factories in the UK, France, Germany and the US and other countries. It's been a long process and countries without the mandates or means financially do what they need to do for now.
@@user-vp1sc7tt4m
My comment was meant more for how someone set up a company then let it grind itself down into the dirt.
Most of these videos show a brick floor, at least a solid floor, but they show no signs of having ever been swept. scrap is scattered around. Care of the workplace cost very little to no money.
The machinery is just this side of junk and there is nearly no care for the workers safety. This does cost but requires some foresight.
I had a machinery book dating from the 1910s that mentioned worker safety if for no other reason. because it cost the employer to replace an injured worker.
Steel fettuccine and cannelloni made the old fashioned way.🙊
Must be where GM gets its frame steel from
Most likely Ford
just spend a fraction of your profit replacing Jandles for saftey Jandles.
To all you that dont know every he strikes a weld he closes his eyes welders do it all the time
For tacking something... Not for welding a seam
What makes it not rust after all that water?
Depends on the type of steel used. The heat of the processes drives off most of the water, but once cooled and with enough exposure, rust might begin to take hold on the finished tubes.
Structural steel like this, that is prone to rust, is usually shipped to the customer with a light film of grease/lubricant on the outside which mitigates rust. All of that is cleaned off with solvents prior to priming and painting or powder coating.
With all the garbage and debris scattered around it's clear the employees do not take pride in their work. Would not trust the quality of the end product.
My stomach overturns seeing this mess.
No one sweeps?
No PPE what so ever. Improper forging heat.
Bear in mind that most of these workers are probably slaves; ripped-off by the boss on every front.
Oil can!
Be blind soon
Thats his secret he already is.
junkyard making more junk to make junk
Come with me, and you'll See, A World of OSHA violations.
Love the Willy Wonka Chocolate Factory reference! I immediately played the Oompa Lumpa tickety boo lyrics in my mind after reading your comment!
It's also a Diesel Creek reference
FF 7 min first half boring
This is a junk yard ? Disgusting.
What a dump. Don't they clean up anything? Must be in Pakistan.
America must buy this to build aircraft carriers it is of such high quality.😆