“The first step in solving a problem is knowing you have one…”
Introducing PDCA based problem solving into a lean, global supplier of steel castings

Esco Corporation is a privately held company that has been supplying cast, formed and fabricated steel products to industry since 1913. An innovator in manufacturing and design of products for mining, construction, mineral processing, forestry and numerous other industrial applications, reinventing itself to remain competitive has long been a key strength of the company. Esco’s manufacturing facilities have been engaged in local continuous improvement activities since the mid-1990’s, especially within the casting groups. Continuous improvement became a key corporate strategy for all parts of the enterprise in 2003 and a by-product of these efforts has been strategic interest groups that concentrate on the global development, testing and introduction of new lean activities and concepts inside Esco.

After a brief introduction on Esco, this presentation will chronicle the story of one of Esco’s SIG teams that took on the task of developing a systematic problem solving tool that could be used in all facets of the company to solve everything from simple to complex problems within the enterprise. It will touch on past unsuccessful attempts to introduce such a tool, on how this team approached the challenge differently and on changes to both the program and to the introduction/training roll-out that have made this a much more successful implementation. Lessons learned from a member of the corporate development team as well as a shop floor trainer and implementer will be included in the presentation. An emphasis and possibly a brief demonstration of the value of keeping some fun and interactivity in the training will likely be included in the presentation.

ESCO Corporation is an international group of companies that manufacture engineered metals parts and components for industrial machinery. ESCO creates innovative products that solve the toughest technical problems. ESCO produces both proprietary and non-patented products that set the standard for quality wearparts. We also manufacture specialized parts and components to customer specifications.

Bradley Robertson, Continuous Improvement/Technical Manager

Bradley Robertson is the Continuous Improvement/Technical Manager of Esco Limited's Port Hope foundry and has been engaged in continuous improvement activities on the site since 2000.  A lifelong resident of Ontario, Brad Robertson is a graduate of Queen’s University in Kingston Ontario with a Bachelor of Applied Science (Mechanical).  After working as a design engineer for an electronic supplier of military and  communications  gear,  Brad joined Esco Port Hope in 1992  to design fabricated and cast products including shovel dippers  and recycling , primary metals and structural rigging castings .   Through engineering, maintenance management and eventually quality and technical roles, Brad has had the opportunity to apply Toyota Production System and Management concepts in many areas of Esco's manufacturing, engineering and office functions as well as in other Esco facilities.  He is an original board member of the Northumberland Manufacturer's Association and leads their Strategic Focus Group on High Performance Manufacturing.  Brad has been fortunate to experience and participate in leading a traditional batch manufacturing plant through the first stages of it's journey from a mass production factory to an ever learning enterprise.