National Projectile Factory (NPF) 1915 - 1917

National Ordnance Factory (NOF) 1917 - 1919

Preliminary

The Factory was one of many large National Projectile Factories, laid down in the Autumn of 1915. It will be remembered that in the Summer of that year there was a very serious shortage of High Explosive Shell.It had become quite evident that the then existing establishments of the Ordnance firms already overburdened as they were with orders for every kind of War Material, would be inadequate to meet the enormous demands for Shell which the "War of Position" had shown to be vitally necessary to the success of our Armies. Accordingly, in July,1915,Messrs. Cammell, Laird & Company, Ltd., among a number of big firms, were approached by the Government and asked to undertake the building and management for them of a National Factory. The first negotiations between the Ministry and Mr. Hichens,Chairman of Messrs. Cammell, Laird & Co., Ltd., took place on July 16th, 1915. On July 23rd, the firm put forward a complete scheme and A preliminary estimate to the Ministry for the erection and management of a Projectile Factory capable of producing two thousand 9.2 Shell and six thousand 6" Shell per week. Mr. Hichens had intimated to the Government that Messrs. Cammell Laird & Co., Ltd. would undertake the design, erection and management of the factory without any remuneration commission or profit of any sort or kind, which offer was accepted.

Site

A site at Nottingham was selected (though by no means ideal as regards the nature of the ground) for several reasons:

• Because adequate labour was at that time obtainable in the town owing to local industries having been hard hit by the War.
• Housing accommodation was available, which was not the case in any of the districts adjoining either Messrs. Cammell, Laird & Co. own or allied works.
• Railway facilities were good.

Further, the Corporation had, in the most public-spirited manner, promised to provide the necessary land free of cost, for the duration of the War and six months afterwards.

The first sod was cut on August 19th. 1915.

Erection & Equipment

The design, equipment, and arrangement of the Factory was undertaken by Mr. J. M. Allan, the Managing Director at Sheffield, and the work in connection therewith was performed by Messrs. Cammell, Laird & Co. Engineering Staff under Mr. DM. Anderson as Chief Engineer. Mr. Anderson also super-intended the erection of the Factory and the installation of the whole of the machinery.The policy adopted by Mr. Allan of ordering strong and substantial machines of English make and of the best possible type for the operation for which they were required, was, in spite of slight extra initial cost and some delay in delivery, more than justified by the results obtained. Many of these machine tools were specially designed by Mr. Anderson.The erection work was pushed on at a remarkable speed, considering the shortage, which at that time was very acute, of structural steel work and machine tools.

Foundations:

Foundation work presented many difficulties. The land was below flood level, and was entirely composed of made-up ground, fully half of which had to be tipped and levelled before any progress could be made.Throughout this first Winter of 1915/16, the weather was exceptionally bad and floods were abnormally high (as photograph No.4 shows), which delayed considerably the excavation work for the Power House and Forging Press foundations. By September 25th, however, the first ironwork was erected, and by April 1916, about half the necessary Shell Machines had been delivered and production work commenced in a preliminary way.Mr. A.S. Bailey had been appointed General Manager of the Factory.The main work on the production side during the Winter of 1915/16 was the engagement of Staff and Labour and the design and preparation of the tools and gauges.

Staff

Neither of these tasks could have been undertaken at a more difficult time. Staff had to be engaged from all over the Country without any knowledge of the men; further, no one who had had previous experience of shell work was available. To facilitate training, therefore, a number of foremen were given an insight into shell making at Messrs. Cammell, Laird & Co own works in Sheffield. It was realised at once that owing to the shortage of men, the machining of both the 6" and 9.2" Shell would have to be done mainly by female labour.

Female Labour

The engaging of over 4,000 women, very few of whom had ever seen the inside of a factory before, was placed in the hands of Miss Allan, who had been appointed Women's Welfare Supervisor. Had there been plenty of time for training and had it been possible to start up gradually, difficulties would not have been so great, but as it was, large numbers of women had to be set to work at once as soon as machines were installed, so that every detail in the organisation had to be complete. This made the task a very different one from extending an existing factory, and more so, as it was not a district in which this class of work had been done previously. Great credit is due, therefore, to Miss Allan and to the Works Staff that so many women were acclimatised and made proficient in a very short space of time.

The factory led the way, to a very great extent, in the dilution of Labour. All the overhead and floor cranes were operated from the very commencement by women. Women were employed on all machining operations of both 6" and 9.2" Shell, and by degrees the skilled men who acted as Toolsetters were replaced by women. Further, many operations in the Tool Room which had previously been considered only skilled men's work were performed entirely by women.

Afterwards, when the change over to Gun Work took place, a large number of women were again employed on the machining operations and proved themselves capable of both doing some of the finish turning operations on the Tubes and also of using Vernier Gauges and Micrometers successfully on examination work. Further, the whole of the operations on the Breech Ring and Breech Bush of the 6" Gun, including several intricate and highly-skilled milling, boring and screwing operations, and the cutting of the "Welin" thread, were performed by women.

Tools & Gauges

Tool and gauge orders had to be placed in the most unlikely places, owing to the fact that all the recognised and experienced gauge-making firms were already overburdened with Work, and owing to the late delivery of machines ordered for the Factory Tool Room.

Changes of Programme

The original capital cost of the factory was very much added to by changes of programme,which the state of War and of munition supplies made necessary. First, there were certain alterations, mentioned later, in the design of 6" Shell, then the change over from Shell to 18-Pounder Gun Manufacture, and finally the entire conversion and fresh laying out of the factory for 6" long range Gun manufacture.

These different periods of production will now be taken separately.

During the construction period the design of 6" Shell was entirely changed twice. The equipment was prepared for the 6" ,Mark XVI, a shell with a loose head. On February 10th ,1916 information was received that the 6" Mark IV, Shell would have to be made instead. This involved the greater part of the tool and gauge work being done over again. Just as this was completed, instructions arrived that the Mark IV, would not be required, but instead, the Mark III., a bottled shell, and that temporarily the manufacture of the original Mark XVI ,was to be carried on in two bays of the shop. The manufacture of the Mark III, Shell involved not only a complete alteration of layout, but also the installation of Hydraulic Nosing or Bottling Presses, which had then, at that late stage to be ordered. The Shell Plant was laid out in 21 bays, each 32 feet wide, nine bays forming the 9.2 Shop and twelve bays the 6", with two single rows of machines in each bay, making in all some 3½ miles of machines. The layout was arranged on the most up-to-date quantity production lines, so as to give a perfect flow of work from the Forging Presses to the Bond Room. Special attention had been paid to handling and transportation facilities, both as regards electric overhead and floor cranes, with a view particularly to making the work easier for women; in fact, it is questionable whether any other factory in the Country was better equipped in this respect.

By May 27th,1916,the first 6" Shell was completed and passed into bond, and by May 31st, the first 9.2 Shell. By July 15th, 1916, the output for which the 9.2 Plant was laid out, viz., 2000 per week, was reached. By August 19th, twelve months from the date on which the first sod was cut, 17842 9.2 Shell and 23519 6" shell had been delivered. The speed with which output had been worked up during this Summer helped the Ministry of Munitions very materially to maintain the supply of High Explosive Shell necessary for the British Offensive, of that year, on the Somme.

By September 23rd the output of 6000 per week, for which the 6" plant was laid out, was reached. During the Winter of 1916/17,the output of 6" and 9.2 Shell was more than doubled, the production of 9.2 Shell reaching 5000 per week in March. Owing, however, to shortage of steel, 9.2 billet supplies were stopped in February, and from hence forth the factory was mainly dependent upon forgings from an overseas source, with a consequent increase in cost of production. From April,1917, the output of 9.2" Shell was, on instructions, gradually reduced as the preparations for repairing and manufacturing 18 Pounder Guns proceeded.

During the early part of the Summer 1917, 97000 149 m/m Shell were completed in the 6" Shop for the Italian Government.

In July, information was received from the Ministry of Munitions that the whole of the 6" and 9.2 Shell Plant would be gradually removed to Lancaster in order to make room for the 6" Gun Plant, which was to be installed in its place. The 9.2 Shell Forging Presses were dismantled in August, and the 6" at the end of September. On October 20th 1917, 6" Shell output reached the highest figure of 13500 per week, after which the dismantling of the plant began. On October 29th 1917 the last 9.2 Shell was delivered, making a total of 209657,out of which the total scrapped for machining defects was only 3.22 percent, of deliveries. During the Winter 1917/18, as the 6" Gun Machines came in, Shell machines were gradually taken out and despatched to Lancaster, and the numbers employed were rapidly reduced. Finally, by June 11th,1918 ,the last 6" Shell was bonded and Shell work finished. The total number of Shell delivered from the Factory was:

9.2 Shell	210262
6" Shel1	685801
Italian Shell	97086
Total	993149

 

Not one "lot" of 9.2 ,6" or Italian Shell failed in the Firing Proof Test.

The numbers employed on Shell when at full output were:

Men-skilled and unskilled	2200
Women	4300
Total	6500

Steel required per week for the full output of Shells was:

9.2	812 tons
6"	886 tons
Total	1698 tons

Each week 550 tons of Steel Turnings and 120 tons of Steel Scrap Ends were sent out of the Factory. The cost of production of both 9.2 and 6" Shell was exceptionally low, with the result that during the eighteen months a very large saving was made to the State which fully paid for the original cost of the Factory.

18 POUNDER GUN WORK

Superintendent Mr. F.Rostance Assistant Superintendent Mr. J. Archer Head Foremen Mr. H. Morrell Mr. A.N. Greenall (Mr.W.Goodall took Mr.Rostance's place as Superintendent of Millwrights).

In March,1917, the first intimation was received that the Ministry would, owing to a serious shortage of gun-repair capacity in the Country, require the Factory to undertake repairs to 18 Pounder Guns, and also the manufacture of certain miscellaneous gun parts. It was naturally felt at the time that what the Factory was asked to tackle was a very big undertaking. None of the staff had had any previous experience of Gun Manufacture at all, and men who had were unobtainable. The success which was eventually achieved would not have been possible in such a short time had it not been for the generous way in which existing gun-making firms assisted by placing their experience and information at the disposal of the factory. In particular, the Coventry Ordnance Works were most helpful ,and spared neither time nor trouble in giving both the fruits of their experience and practical assistance. Gun Manufacture, it will be remembered, had always been looked upon as a very highly skilled and exclusive class of work, requiring lifelong experience. In fact, in pre-war days, factories which had started such work, even with experienced staff, had only developed gradually, and only after some years of work had they been regarded by the authorities as reliable. The factory then was called upon to learn practically a new trade and to develop in a few months what had previously taken years.

The plant had to be fitted in three bays of the 9.2 Shell Shop. Whilst the preliminary work was being done instructions to make new 18 Pounder Guns as well as to do repairs were received, which made alterations to the lay-out necessary, and involved delay. Finally, whilst the installation of Machines was still proceeding, intimation was received that the whole factory would be required for 6" Long Range Gun Manufacture. The 18 Pounder plant, therefore, worked under considerable difficulties for twelve months during the transition period, whilst all the preparatory work for the 6" Gun was being carried out, and whilst Shell Machines were being transferred to Lancaster. As a consequence, costs could not be kept down to what they would have been had circumstances been normal. The plant was laid out for 20 guns per week, and the output actually reached was 34 guns per week, repaired and new combined. The manufacture of new guns Which was carried on simultaneously with repairs, was delayed at the commencement and eventually very much curtailed because the greater part of the machines ordered for for this new work were never delivered The factory was, therefore, mainly dependent upon guns coming back from the Service for repair the supply of which was always intermittent. The layout drawings were completed in a very short time in spite of the inexperience of the whole of the staff, and tool and gauge work put in hand.

Many of the machines offered for this gun work were in the judgement of the Factory Management, quite unsuitable, and it was necessary, therefore, to set to work to alter many of the old 9.2 Shell machines to adapt them for gun work, which was accomplished very successfully. By June 20th, 1917, the repair plant was completed, and by August 18th the first ten repaired guns were delivered. By September 8th an output of 20 repairs per week, for which the plant was designed, was reached, viz., ten weeks after the completion of the plant. By December 4th,1917, the first four new 18 Pounder Guns were delivered. The plant worked on throughout the Winter 1917/18 whilst the rest of the shop was being prepared for the manufacture of 6" Guns.

The dismantling of the 18 Pounder plant for transfer to Leeds, in order to make room for the 6" Gun Plant, was commenced at the beginning of June, and by the middle of July,1918,work had finished. The total number of 18-Pounder Guns delivered was:

Repaired	588
New	354
Total	942

On June 20th, 1917, the first notification was received from the Ministry that the factory would required to undertake the manufacture of the new 6" Mark XIX Field Service Gun. This was a Long Range Gun which had been proved to be very efficient in Service, and which was urgently required in large numbers. The layout was to be arranged for an output of 100 guns per month, and it therefore became evident at once that the whole shop would be required to accommodate the necessary machines, and that the Shell and 18 Pounder Gun Plant would have to be removed.

The lay-out and foundation drawings were prepared in Sheffield by Mr. H.C. Loving, who succeeded Mr . Anderson as Chief Engineer when the latter was appointed to a Controllership at the Ministry of Munitions. The tool and gauge drawings were executed at Nottingham. The work was put in hand at once and steps were taken to train the Supervising Staff, in which Considerable assistance was received from information supplied by the old-established gun factories. Delay in obtaining delivery of the necessary machine tools, which were ordered at once, was inevitable. For the big new machines it was necessary to lay deeper foundations, and to remake practically all the floors. A progressive programme had therefore to be arranged whereby the Shell Plant was gradually stopped and machines despatched to Lancaster as the foundation work proceeded. It was arranged that the Shell plant and the 18 Pounder Gun plant should be retained as long as possible in order to enable the labour to be kept together ,and also to act as a training ground for the 6" Gun work.

The Labour problem throughout was most difficult, as only a small proportion of the labour employed on Shell work was suitable for the more highly skilled Gun work, and skilled men with sufficient experience were almost unobtainable. Further, during the transition stage it was very difficult to keep the staff, whom it was necessary to retain for the new programme, employed.

On October 1st, 1917, the name of the factory became THE NATIONAL ORDNANCE FACTORY (NOF), instead of THE NATIONAL PROJECTILE FACTORY (NPF).

By the end of-December, 1917,the number of employees was reduced to 3,200. 71 6" Gun Machines had been received out of 350 required. A certain amount of experimental work had been started, and a contract for rough machining 6" Mark XIX, Gun Forgings, Jackets ,A Tubes, and Inner A Tubes had been undertaken in order to assist Messrs. Vickers, of Sheffield. Foundation work was proceeding rapidly and the old Shell Paint Shop had been closed down for Alterations and for a new bay to be added for 6" Gun Breech Bush and Breech Ring manufacture. By the end of March, 183 6" Gun Machines had been delivered out of the 350 ordered.

During May, 1918, the first pair of new gun tubes were built together, and the first inner tube was tapped out of a 6" Gun sent for relining. About the same time an order was received for 8" Howitzer Breech Rings for Messrs. Hadfield at the rate of five per week. Early in June the factory was instructed to-undertake, to a limited extent, 9.2 Howitzer repairs, in addition to the programme already arranged. Throughout the early part of the year and the summer of 1918, great difficulty was experienced in obtaining delivery of certain of the most essential gun forgings, though plants had been put down in different parts of the country to supplement the output of the old established Forge Masters, who, owing to the vast demands for Marine-and Ordnance Forgings of every kind, could not possibly provide for this big new 6" Gun Programme, which involved the supply of some 400 large forgings. Early in June the first 6" Jacket was built with the first pair of Tubes, and on June 25th the first 6" repaired gun was rebuilt with a new inner tube. By the end of July, 314 machines had been delivered and 220 were ready for running. At the end of August there were still 28 machines undelivered. On September 9th the first 6" gun repair was completed and despatched. On September 21st the first new 6" gun was completed and despatched. By the date of the signing of the Armistice the factory was just getting up to an output of eleven guns per week, and was beginning to get a regular flow of work, and there is little doubt that in a few weeks time the output would have been up to that for which the factory was laid out.

Far fewer difficulties were encountered in the manufacture of this gun than were to have been expected with an inexperienced staff . The Firing Proof Test, at which there were no failures, has shown the Nottingham Guns to have been well made. Their general behaviour at proof and finish have been commented upon by the Inspection Department as comparing very favourably with those from old-established Gun Factories.

The number of machines engaged on actual Gun manufacture was as follows:

Boring Machines	131
Centre Lathes	96
Boring Mills	16
Milling and Drilling Machines	32
Planing Machines	41
Slotting and Shaping Machines	17
Rifle and Combing Machines	12
Wire Winding Machines	5
Total	350

Overhead electric Cranes Installed:

10 tons capacity	1
7 ½ tons capacity	5
5 tons capacity	15
3 ½ tons capacity	39
2 tons capacity	9
Total	69

Labour employed

Skilled Men	600
Semi-and Unskilled men	800
Women	700
Total	2100

Power plant installed consisted of: Six Babcock and Wilcox's Water Tube Boilers, each evaporating 20000 pounds of water per hour. Fitted with mechanical stokers. Three triple expansion Three cylinder Bellis & Morcom Engines, 1050 BHP, coupled direct to Three Siemens DC Generators, 750 kilowatts. One Mixed Pressure Steam Turbine, coupled direct to Siemens Alternator. One Briten Westinghouse Geared Turbo Generator ,1500 kilowatts. The last set was ordered for the new 6" Gun Programme, but had not been delivered at the end of 1918. Invaluable assistance was given in the early days of the factory by Nottingham Corporation who provided three second hand sets of Willans & Robinson's Engines from their Power Station to be erected in the factory Power House. By this means the factory was enabled to make an earlier start than would have been otherwise possible, had it had to wait for the new sets. They also undertook the running of the Power House for the factory until the end of 1916.