Sidebar: A Sewing Machine, A Razor Blade, and Buzz Bombs

As orders for buzz bombs kept rising, so did the need to boost production. The task was straightforward: cut thousands of buzz bomb fuses, each measuring 2 to 3 inches. The women on the assembly line used a jig—a simple device—that guided the fuse for accurate cutting. But with 10,000 feet to process, it was like trimming spaghetti with fingernail clippers. It was a slow, tedious, and never-ending job.

Lawrence Brown, always the problem solver, examined the operation and saw a challenge. So, he rolled up his sleeves and got to work. He grabbed a Singer sewing machine and replaced the needle with a razor blade. Then he set up an automatic feeder that slid the fuse in, and, with each downward stroke of the razor blade, the fuse was cut to the perfect length. It was elegant, efficient, and worked like a charm.

But sometimes a good solution can create a new problem. One day, a visiting chemistry professor—a self-proclaimed fireworks expert—came to inspect the plant. He took one look at Brown’s invention and turned pale. “You’ve got to do something about that,” he warned. “It’s kicking up powder with each cut.”

So, Lawrence once again adjusted the setup. Where the fuse was cut, he drilled a hole beneath the machine. Any excess powder dropped straight through to the outside, safely away from potential sparks. Problem solved. Production saved.