As already intimated in a former chapter, the revolution in the methods of carrying on the shoe trade in all its branches began with the introduction of the sewing machine in 1852. Slight advantages in the way of improved kit had been gained before. As early as 1834 an "edge iron" was introduced to polish - or "sleek," as the shoemakers called it - the heavy edges of "welts" and "imitation," in place of the old-fashioned "shoulder-stick." This iron is in the writer's possession, and upon it is inscribed - "This is the first double-iron ever made; invented by John Johnson, and made by Aaron Tufts, Lynn." The term "double" meant that it had two "shoulders," one on each side-one for the thickest edges, the other for the lightest. As the iron could be heated, this "hot kit" gave the edges a polish and solidness which the wooden "shoulder-stick" could not do. A veteran shoemaker informs the writer that he used such an iron before the above date. "Soap stones" were also used, to some extent, to polish the edges in making "heavy work." Several other small inventions, each one slight in itself, improved the art of the shoemaker, making the work of his hands better as the years went on. Two more important improvements were made prior to 1852 - patterns for "rounding on " the soles, and "block" lasts, which superseded the use of "instep-leathers." (This piece of kit was inadvertently omitted in the list given in a previous chapter.) The "instep-leather" in the hands of the old-time shoemaker was not exactly an enchanter's rod; but he could do wonders with it by skillful manipulation. If he wished to make a "slim" shoe he would not push it so far toward the toe. If the boss told him to make 'em "full" then no such caution was used, and perhaps a wedge would be driven in besides. Good workmen had several instep-leathers, so as to meet all emergencies; but the poor workman - poor in skill and poorer in purse - often had but one, which was made to play fast and loose along a sliding scale of geometrical proportions between the widest extremes of "slim" and "full." One can imagine the comments made as a lot of these shoes were examined by the "boss." "Uncle Jim! what did you 'sew these shoes out' so for; did n't you have any instep-leather?" Then the boss would try to get his hand down toward the toe, but could n't. Then he would take up another pair, and put his hand in each shoe by turns. "That's about right, Uncle Jim, full enough, plenty;" and so, perhaps, Uncle Jim consoled himself with the thought that he had made the average about right. One lot of these shoes would sometimes fulfill pretty much all conditions of "fullness" and "slimness." And so one would hear in the retail stores - "Have you a pair of fives, slim?" The dealer, not knowing exactly where to look, would examine all the fives he had, and when he found a pair that he supposed were about right, one of them could be got on the foot, but the other could n't. This illustrates the science of those times. The "block" last swept away this relic of mechanical barbarism, and brought uniformity of fullness out of the chaos of uncertainty, by making it necessary for the workman to "last" the upper down snug over the block. The instep-leather thus came to an end, and no longer tempted the genius of the sons of Crispin. The sole-pattern gave uniformity of shape and width, as the block-last had made certain the uniformity of fullness, and so these two essential conditions in the shoemaker's art were secured. It is now but little more than thirty years since the practice of making lasts of regularly graded widths was adopted. Before this time, shoes were classed in two general divisions, wide and narrow, full and slim, the wide being generally full, and the narrow generally slim, but not always. As already shown, a good deal of uncertainty hung over it. When some one having an eye to method made known the plan of labelling the narrowest lasts used "A," next in width "B," and so on to "D," a long stride was taken, though it now seems so simple a thing. What was called the '"Kimball" last was introduced about 1848. This was the first really scientific last used in the making of ladies' shoes. Each set of these lasts had "sliding blocks" that fitted into a groove in the last, each block marked "slim," "medium," or "full." This gave all grades of fullness. Other block-lasts were afterward used, and more especially when the work came to be done in the large factories. This block was sawed out from the top of the last, and regular graded fullness was secured by having the uppers lasted down snug to the block when it was in its proper place. (Similar block-lasts had long been in use in making men's boots and shoes.) This shut out all uncertainty, and left the workman no room for the display of originality. As, by this arrangement, each last was made of the required fullness there was no chance for any mistake that might have come from the use of the wrong block, when there were three or four of them of different degrees of fullness belonging to each set of lasts. These lasts were also graded according to width; each last of each set being marked. There were four grades, A, B, C and D; A representing the narrowest, and D the widest. Almost simultaneously with this improvement in lasts, was the introduction of the "Congress Boot." This invention consisted in the insertion of a "rubber gore" on either side of the top of the boot. Its elasticity obviated the necessity of the "lace," which is indispensable when non-elastic material is used. This style became very popular on account of its convenience. The patent for Essex county was granted to Charles Winslow, of Lynn, near the close of 1848.
HANNAH BINDING SHOES. Poor lone Hannah,Sitting at the window, binding shoes. Faded, wrinkled, Sitting, stitching, in a mournful muse. Bright-eyed beauty once was she, When the bloom was on the tree: Spring and winter Hannah's at the window, binding shoes. Not a neighbor Passing nod or answer will refuse, To her whisper, "Is there from the fishers any news?" O, her heart's adrift, with one On an endless voyage gone! Night and morning, Hannah's at the window, binding shoes. Fair young Hannah, Ben, the sun-burnt fisher, gayly woos, Hale and clever, For a willing heart and hand he sues. Mid-day skies are all aglow, And the waves are laughing so! For her wedding, Hannah leaves her window and her shoes. May is passing: Mid the apple boughs a pigeon coos, Hannah shudders, For the mild southwester mischief brews, Round the rocks of Marblehead: Outward bound, a schooner sped: Silent, lonesome, Hannah's at the window, binding shoes. "T is November, Now no tear her wasted cheek bedews. From Newfoundland Not a sail returning wilt she lose, Whispering hoarsely. "Fishermen Have you, have you heard of Ben?" Old with watching, Hannah's at the window, binding shoes. Twenty winters Bleach and tear the ragged shore she views. Twenty seasons: Never one has brought her any news. Still her dim eyes silently Chase the white sails o'er the sea: Hopeless, faithful, Hannah's at the window, binding shoes. But the introduction of the sewing machine ended all this, and soon were seen the stitching shops in different parts of the city, (Lynn became a city in 1850,) and the peculiar rattle of the machine made a new music more suggestive of industry than of the harmony of sweet sounds. These shops were sometimes small buildings standing by themselves, but more frequently rooms fitted up in some part of the shoe factory. But these machines were destined to have a wider use than that afforded by the stitching shop of the shoe manufacturer. They soon found their way into almost every house to be used, not only for the various kinds of work required in stitching "uppers," but for every kind of sewing needed in the household. Soon after the sewing machine was brought into use the whirligig of time brought heeled shoes - for ladies - again into fashion. This style had prevailed for some time prior to 1830, when the "spring heel" gradually led the way to no heel at all, a few years after this date. About 1855, the demand for heeled shoes again began, and with this demand began the practice of employing the "jours" to work in the factories of the manufacturers to "heel" the shoes. From this grew up that specialty in the shoemaker's trade known as "heeling." A man working exclusively at this branch of the craft soon became an expert, even though he knew nothing else of the art of shoemaking. The "heeling" was afterward subdivided into "nailing," "shaving," "blacking" and "polishing; " and from this gradually came that minute division which is now the marked feature in this business, distinguishing the new order of things from the old. Before this time the shoemaker got his "stock" in the crudest form; sometimes cutting the soles from part of a side of leather, and making the shoes complete in everything pertaining to the "bottoms," so that when it left his hands it was ready for the foot of the wearer. The period was now reached when the great change took place. The revolution in the shoe business occurred during the ten years ending 1865. From 1855, or a little later, the workmen began to leave the "little shop" to work in the factories of the manufacturers; and in a few years vacant shops were seen all over the city, until most of them were transformed into henhouses or coal-pens, or were moved and joined to some house to make a snug little kitchen. Some of the larger ones were sold to men of slender means to be finished off into a tenement, eked out, perhaps, by a small addition, that made it look very much like a house. A few still linger among us, characteristic mementoes of the olden time; and fewer still are occupied by the small number of veteran shoemakers - for the most part - who could not find it an easy thing to break up the associations of long years, and so "stood by" the "old shop," and did a little "hand work" for those manufacturers who made no "machine work," or whose business included both kinds. The introduction of the McKay machine, in 1862, made as complete a revolution in the work of the shoemaker as the stitching machine had done for the binder. To those not familiar with the "craft" it may be interesting to know why this was so. The machine-made shoe is, as a matter of necessity, a doubled-soled shoe; and, hence, took the place, in a great degree, of the old hand-made "welt." This hand-made welted shoe required two seams, the inner seam, or the sewing-in of the welt - and upper - and the "stitching," or sewing together of the welt and the outer sole. The average time required in sewing each of these seams was not less than fifteen minutes, or half an hour for each shoe, or an hour for each pair. The McKay machine, by sewing directly through inner sole, upper and outer sole, substituted one seam for two; and when it was worked by "power," such was the expedition of its movements that eighty pairs an hour have been stitched upon it, giving less than twenty-three seconds to each shoe. The McKay machine was first run by foot power. The introduction of steam power into the shoe factory did not become general until some years after the McKay machine, came into use. Steam, as a motive power to facilitate the making of shoes, was first introduced into the factory of John Wooldredge, in 1858. It was used to run a machine for making heels. Mr. Wooldredge also merits the distinction - as mentioned in a preceding chapter - of having introduced the sewing machine into Lynn. Soon after the close of the war, in 1865, the introduction of steam became general in all the large shoe factories. The use of the McKay machine suggested the economy of steam power; and it also suggested, and almost made necessary, a dozen minor inventions - mostly the products of the mechanics engaged in the craft - some of them exceedingly ingenious and effective in saving labor. This brought about the division of work already alluded to, and classified it into separate departments. To show how minute is the division of labor in the shoe factory of to-day, the following list, showing the number of operatives employed upon the different parts, will well illustrate: Beginning with the sole cutter - 1, stripper; 2, sole-cutter; 3, sorter; 4, tier-up. B eginning now with the upper stock in the cutting-room - 1, outside cutter; 2, lining cutter; 3, trimming cutter; 4, dier-out. When the uppers reach the stitching shop they pass - 5, into the hands of the lining maker; 6, closer; 7, seam-rubber; 8, back-stayer; 9, frontstayer; 10, closer-on; 11, turner; 12, top-stitcher; 13, button-hole cutter; 14, corder; 15, vamper; 16, button sewer-on. The uppers and bottom stock are now taken to the lasting - or finishing - room. As we have already seen, the bottom stock has passed through four processes, ending with the tier-up. These, added to the sixteen through which the uppers have passed, make twenty before they reach the hands of the stock-fitter. From this point the process goes on - 21, stock-fitter; 22, laster; 23, solelayer; 24, stitcher; 25, beater-out; 26, trimmer; 27, setter; 28, liner; 29, nailer; 30, shaver; 31, buffer; 32, burnisher; 33, channeller. To these is sometimes added a channel-turner. Boys usually perform these minor parts. And these various processes, minute as they seem, give but a partial view of the multiplied divisions that have already taken place. To illustrate this still further: In some of the manufactories the "nailing" and "shaving" are done by a McKay "nailer and shaver." A boy "sets" the nails, a single stroke of the machine fastens them, and a circular motion of the machine shaves the heel with geometrical exactness at one cut, and in an instant of time. The boys who perform these minor parts gain a nimbleness of manipulation that gives them an expertness hardly possible to be gained by older hands. These forty, more or less, distinct operations will soon become fifty, and the end is not yet. But perfection is never reached. New inventions still spring from the brain of the ingenious mechanic, and inferior contrivances drop into oblivion, or find their way to the cabinets of antiquarians. All the adjuncts of the shoe business grow up, chiefly, during this transition period. Among others was-
W. W. George began business in 1879. He is doing a large and increasing business. Charles H. Libbey & Son began business in 1879, on Union street, near the head of Washington street. Rufus E. Hilliard began business the present year (1880) in the basement of Sweetser's Block, corner of Oxford street and Central avenue. His trade has rapidly increased, and he is now doing a large business. T. W. Tyler & Co. have lately taken up the business of cutting a cheap grade of soles, in connection with their business as dealers in rubber goods. Besides the business done by those who confine themselves to this branch of trade exclusively, there are thousands of pairs cut and sold annually by some of our large shoe manufacturers, besides those needed for their own use. Some of these, whose business requires a heavy grade of soles, accumulate a stock of a lighter grade. These they sell. Others, whose trade is in a cheaper kind of shoe, have a surplus of high-priced soles which they dispose of. This business is almost exclusively a Lynn industry. Very few soles are cut - to sell - elsewhere. Haverhill does something in this line; but her trade, as compared with that of Lynn, is insignificant. The trade of or city in cut leather reaches all over the country, and it is estimated that from one-third to one-half of the entire product is sold to dealers in other places. As already mentioned in the "General Review" the first sole-cutting machine used in Lynn was invented by Richard Richards, of Lynn, in 1844. Shortly after, George Foster made some improvements in this machine; and still later John Thompson, of Marblehead, added some new features, which were patented. These machines had two revolving knives, each blade turning and cutting one side of the sole alternately. One or two other machines, acting on different principles, were used for a short time. In 1860 David Knox, an ingenious mechanic of Lynn, made a radical improvement in the machines in use, for which he obtained a patent. The peculiarity consisted in the reciprocal motion of the two knives, which, playing on a short arm, cut alternately each side of the sole, as each blade descended by turns into the same groove of the cutting block. This machine soon superseded all others in use. To illustrate the economy of labor which this machine brought about, it is only necessary to say that the old-time cutter, standing at the "leather-board," could cut by hand - if smart - ten middling sized sides of leather a day. An active man, with one of these machines, can cut two hundred and fifty sides, after they have been cut into strips by the "stripper," as described in a previous chapter. These machines have been generally run by steam power in the large establishments since 1872. This does not much accelerate the movement; but it saves the strength of the operative, and especially the muscles of the right leg, upon which there was a constant strain when the machine was run by "foot power;" and it goes, besides, with a steadiness of motion that saves the wear and tear of the machine. In the "General Review" - page 19 - the "stripper" was mentioned as preceding the "sole cutter." Its use was nearly simultaneous, or followed immediately. The following figures, from a statement prepared by George W. Mudge, who is authority on all matters relating to this branch of trade, will give some idea of the magnitude of this business: "During the past year there has been cut four hundred and eight thousand seven hundred and twenty (4087,20) sides, weighing six millions seven hundred and forty-three thousand eight hundred and eighty (6,743,880) pounds, being a weekly average of seven thousand eight hundred and sixty (7,860) sides, weighing one hundred and twenty-nine thousand six hundred and ninety (129,690) pounds. The estimated number of pairs of soles, embracing men's, women's, misses' and children's, is fifteen millions five hundred and thirty-one thousand three hundred and sixty (15,531 ,360) pairs, being a weekly average of two hundred and ninety-eight thousand six hundred and eighty (298,680) pairs. The value of this leather before cutting is estimated at about $1,900,000. These figures were obtained in 1879, and the trade has largely increased since. The amount of business now done (1880) is estimated at about $3,000,000. As already hinted in a preceding chapter, the outcome of all this is a more perfect product. The work done in Lynn, in every branch of the shoe business, was never so good as at present. The law of adaptation is recognized, and guides every process. There is little waste, and that little is becoming less. Everything is utilized. In short, scientific exactness takes the place of guesswork, and systematic economy the place of wasteful methods.
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