Millions Of Variable Resistors
Millions Of Variable Resistors
Two documentary/sales films showing the history, development, manufacture and use of variable resistors, used in the manufacture of color TV sets and other electronic equipment. Focus in on CTS corporate seal. Dissolve to TV screen, distorted image. Superimpose titles and credits. Dissolve to rolls of copper metal. Dissolve to CU of a variable resistor in a hand. Dissolve to an aerial shot of the plant. Stop motion as variable resistor components are shown. A workman inspects the metal with a micrometer. Round rod is checked with a ring gauge. A hex rod is checked with a micrometer. Rockwell hardness tester checks for hardness. Return to 15 piece parts of the variable resistor. CU of the carbon element. A sign saying "KEEP OUT" hides the secret manufacturing of the carbon element. Sorting of the resistors for tolerance. Sorted resisitors stacked on rods. A sheet of black plastic is sheared, blanked on die cutting machine. Punch press operator checks for defectives. Two end terminals are shown. The terminals are formed from metal on high speed presses. CU of this operation. Inspector checks parts. Gauges, degreasing and plating in vats. Completed terminals. Checking solderability. Rivets are made on header machines. Micrometer checks. A can of rivets is emptied. Ground plate is shown and its strip manufacture on progressive dies in high speed presses. Automatic plating machines. CU of the finished parts. Threaded bushing or thimble fastens the unit to a TV set. High speed six spindle auto indexing auto screw machines turn out these parts. CU of the finished part falling off of the cutter. Bushings are checked with instruments. Finished bushing. The center connector is blanked from metal alloy, on dial feed punch press. ECU of the parts being gauged. Plating machine gives special finish. Noise-free contact surface. Checked for solderability. Finished parts are placed on a conveyor belt. CU of a metal shop plate to keep the unit from rotating. Blanked, formed, inspected and degreased. Plastic plate is formed. Metal contact arm is fixed. Blanked and formed from special alloy, progressive formation shown. Checking with gauges and special instruments. Bins of the parts. The shaft is made on Brown and Sharp automatic screw machine. Woman workers check the parts. Secondary operations. Flat milling of the shaft ends, and micrometer check. The autoplating bath. Finished parts are checked with gauges. Bins of shafts are placed on a conveyor. A C washer is blanked from aluminum. Finished parts. Plated cover is formed from strip in progressive die machine. Finished parts fall into a bin. CU of cleaning baths for plating. CU of beakers as a chemist analyzes the baths. Finished cover sent to assembly department. Switches at the end of the resistor are assembled in production lines. Bases and terminals are assembled on bumping jigs. Pivots are staked. Finger assemble the switch. Cams and springs are assembled and staked. Switch CU with cover. Hands assemble the units. CU of hands preparing die of dial feed stamping machines with customer code. Piece parts for sub assembly. Hands assemble the parts and the camera moves down the line to a finished part. Shaft and stop plate staking on a turntable. Finished parts. Operator carries tote box of parts. Final assembly line of many women in a row. Group leader inspects the order. He puts parts on the line. First is assembly of the base, elements and terminals. Bumper jog bumps the three parts tightly. Visual checking by women. Hands perform the manufacture. Thimble roll over machine operator. Ground plates and bushing are assembled. Riveted assemblies are fastened to bushing and ground plate. Center connector is inserted. Fingers fly. Shaft, drive arm, contact arm are assembled. Lubrication. C washer locks the assembled parts. Rows of finished parts on te lie and hands and machines complete the unit. Inspection department checks each resistor against the order, electronically and mechanically. Finished parts are packed in egg-crate cartons. Box is closed. Box is conveyed to warehouse. Stacks of parts are piled. Boxes are sealed by hand stapler, with ID data packed in each box. Montage repeats the intricate machinery of the manufacturing process. Nice rhythm established here with hands, parts, machines in motion. No narration this sequence, music only. Combination of skilled humans and intricate machinery. Delivery man loads batch of cartons on truck which pulls away from the CTS plant, aerial view of the plant, and The End.