the manufacturing process - esco corporation · 2012-08-30 · turbine technologies group...

THE

Solutions from ESCO

IN THIS ISSUE

The Manufacturing Process

SEPT

EMBE

R

2008

Cores of sand stand ready to be placed in molds to make ESCO® mining teeth.

To be the premier provider of highly engineered, technically rich metal components and solutions for industrial applications.

ESCO Corporation, founded in 1913 in Portland, Oregon, USA, is a global group of companies that manufactures engineered metal parts and components for industrial applications. ESCO is comprised of two operating groups:

Engineered Products GroupInnovation leader for metal wear parts, components and earthmoving products used in global mining, construction, dredging and other challenging industrial applications.

Turbine Technologies GroupResponsive manufacturing partner for precisioninvestment cast components in aerospace andindustrial gas turbine applications.

ESCO MISSION

• Show the strengths and problem-solving capabilities of ESCO’s business groups

• Spotlight ESCO’s successes in the diverse markets it serves

• Communicate the values and traditions that make ESCO unique

• Help build lasting and mutually beneficial relationships with customers

EDGE MISSION

Printed in the USA on100% recycled / 100% post consumer waste paper.

© 2008 ESCO Corporation.All Rights Reserved.

The EDGE: Solutions from ESCOThe Magazine of ESCO CorporationSeptember 2008 Volume 5 Issue 3

EditorJohn Howard

DesignerNatalie Maciukenas

Director of Marketing CommunicationsJodi Walder-Biesanz

The EDGE staff would like to thank the following individuals for their help on this issue:

Jerry Bailey, Kurt Ball, Lonnie Farber, David Larsen, Dale Miller, Paul Pope, Allan Sprawkins, Tony Gutierrez, Andy Rowzee, Mike Schultz, Dave Simpson, Mike Swanson, Hank Swigert and Brad Wannamaker.

The EDGE is publishedin March, June, September and December.

Readers’ comments and suggestionsare always welcome.

EDGE MagazineESCO Corporation2141 NW 25th AvenuePortland, Oregon USA 97210email: [email protected]

To be the premier provider of highly engineered, technically rich metal components and solutions for industrial applications.

Hi John,

I recently joined ESCO as Human Resources manager in Port Hope and I felt I should let you know how impressed I am with the quality of The EDGE. Your team has a great ability to create people’s profiles and the way each article is built is really excellent. Just wish to say “great job” to you and everyone else in your team.

Regards,

Mario Chartrand Human Resources Manager ESCO Port Hope

Editor’s Note:

The EDGE team thanks you, Mario, for your complimentary words. Our last issue, in which eight individuals were profiled in some detail, seemed to be unusually well-received. As a result, we may profile eight different individuals in a future issue. In order to continually improve our publication, the EDGE team welcomes readers’ comments, suggestions and criticisms.

Send us your thoughts:

EDGE Magazine ESCO Corporation 2141 NW 25th Ave. Portland, OR 97210

or

[email protected]

TO THE EDITORCover photo by John Howard

To be the premier provider of highly engineered, technically rich metal components and solutions for industrial applications. To be the premier provider of highly engineered, technically rich metal components and solutions for industrial applications. CONTENTS

4

From Steel Scrap to Sophisticated ESCO® Products

ESCO’s business model begins and ends with the customer. Assessing the needs of customers in the mining, construction, turbine engine and other target markets, and making value-added products to satisfy those customer needs is how ESCO has succeeded as a steel technology business for over 95 years.

This issue of the EDGE provides a simplified, step-by-step description of the process of making steel castings. Our company currently operates a dozen steel foundries around the world making engineered products, plus five investment casting foundries. Each foundry has unique capabilities and specialties. In this magazine, we will look at the manufacturing sequence in ESCO’s steel foundries. Investment casting – the method we use to make high specification turbine components – is so different from traditional steel foundry methods that we will save that description for a future issue.

On the pages that follow you will find descriptions and photographs of the key steps in the foundry process: pattern making, molding and core making, heat makeup and melting, pouring and shakeout, heat treating and quenching, machining and fitting, assembly and inspection, painting and packaging, and final consignment to inventory or shipment to the customer. Of course, these core steps in the manufacturing process are supported by dozens of additional disciplines like maintenance, purchasing, pattern management, supply chain management, engineering, metallurgy, and numerous hiring, training and development programs for shop personnel. It would take a thick volume to describe all the factors that support the making of steel castings. Our intent is not to write a textbook. We just hope this simplified description gives readers a better understanding of how ESCO makes castings.

A casting may be defined as a metal object obtained by allowing molten metal to solidify in a mold. ESCO has been making steel castings since 1913 and we’ve become very good at both the science and the art of designing, molding, pouring, heat treating and finishing durable, long-lasting castings for a variety of demanding applications. ESCO’s 12 foundries together pour many hundreds of tons of steel castings per day for the Engineered Products side of the business. To do so, we melt scrap steel and foundry returns and pour it into molds of sand. After shakeout, flogging, heat treating, finishing, inspecting and painting, we’re ready to ship hundreds of tons of finished ESCO® castings and assemblies to dealers and end users the world over – every day!

A steel foundry is a big, capital intensive, complex and colorful business, and ESCO is one of the very best at it. This step-by-step summary is a tribute to the men and women who daily transform scrap metal and sand into finished castings ready to do the world’s work.

– John Howard, editor

8

INTERVIEW WITH DIRECTOR HANK SWIGERT 16

MICHAEL SCHULTZ: INDUSTRIAL PHOTOGRAPHER 18

SERVICE ANNIVERSARIES 19

6

10

FROM THE EDITOR

12

14

CONTENTS

THE FOUNDRY PROCESS

STEP 2: MOLD AND CORE MAKING

STEP 5: FINISHING

STEP 3: HEAT MAKEUP AND MELTING

STEP 1: PATTERN MAKING

STEP 4: POURING AND SHAKEOUT

ESCO’S STEEL FOUNDRIES

THE EDGE SEPTEMBER 20084

Pattern Making

by John Howard

A pattern is a precise, true-to-size representation of what the steel casting will look like. Once its

dimensions are validated it can be used over and over again to make an almost unlimited number of identical castings.

by John Howard

Above and right: ESCO Portland inventories a huge number of patterns including some very large ones for mining lips.

M A N U F A C T U R I N G

P R O C E S S

THE EDGE SEPTEMBER 2008 5

A large wood and urethane pattern is positioned in a floor mold.

When ESCO engineers – responding to a need in the marketplace – settle upon a new steel casting design, they contract with reputable pattern shops to manufacture the pattern, core boxes and other items needed to form the casting. The computer aided design (CAD) data defining the dimensions and shape of the casting are shared electronically with the pattern shop. Pattern makers, in turn, use this data with CNC programmable machine tools and other machinery to precisely render three-dimensional pattern parts.

Patterns are usually made of wood, plastic or metal. Some have a wooden structure surfaced with fiberglass. Urethane pat-terns are favored for their stability and durability, and are more readily repaired than patterns made of other materials. Steel, the most durable and costly pattern material, is favored for high volume patterns and core boxes. ESCO’s foundries that produce tens of thousands of identical earthmoving teeth, for example, generally use steel patterns and core boxes. Cores are compressed sand inserts that form voids inside a casting. Their shape is just as critical as the exterior pattern shape.

In recent years, ESCO engineers involved in new product development have been able to make trial patterns on-site us-ing state-of-the art rapid prototyping (RP) technology. These temporary, relatively inexpensive patterns of ABS plastic can be made in a matter of hours using fused deposition modeling. They are perfect for making prototype castings for field trials.

Patterns and core boxes represent a big investment, and a ma-jor storage and maintenance challenge. The wooden pattern for a large ESCO mining bucket lip might run $75,000 or more. Metal patterns and core boxes for a single earthmoving tooth style might cost $45,000 or so. And ESCO inventories many thousands of patterns. At ESCO Portland where a very wide variety of castings are produced, over 9,000 active patterns are stored, requiring over 60,000 square feet of warehouse space and a very efficient storage and retrieval system. Some pat-terns are small enough to fit in the palm of your hand. Others measure up to 20 feet in length and weigh hundreds of pounds.

Product design engineers and pattern makers work closely with foundry methods engineers to assure that castings can be poured efficiently and at reasonable cost. Patterns are often modified for optimum manufacturability. ´

Patterns are used to form the shapes of the sand molds


Cores, which are sand inserts that form the interior shape of the casting, are formed in

core making machines. A metal-lined “core box” serves as the pattern for most cores.

Mold and Core Making

by John Howard

Mold wash is fired off of a sand mold in preparation for pouring.


P R O C E S S

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Various methods are used to form sand molds and cores

Core machine operators fill core boxes with special sand mixed with chemical binders. ESCO has taken pains to reduce or eliminate the binders required to form satisfactory molds and cores. The sand is blown or manually packed into the core box and allowed to harden through a heating or chemical process.

Patterns and cores, which define the shape of the desired steel casting, are key elements in making a mold. A typical green sand mold consists of a top (“cope”) and bottom (“drag”) half contained in a rigid metal frame or “flask”. Sand mixed with clay and water is packed very tightly in the flask around the pattern. Often, high quality facing sand is packed directly against the pattern, then the mold is filled with less-critical backing sand. The mold is mechanically jolted, squeezed and/or rammed with pneumatic hammers until the sand is rigid enough to maintain its shape when the pattern is removed.

The mold is also configured with a set of channels through which the molten metal will flow to fill the pattern-shaped cavity. This is called the runner or gating system. Sometimes metal inserts called “chills” are placed at key spots in the mold in order to affect the rate of solidification in those locations.

When the two mold halves are carefully joined, containing the pattern-shaped cavity, cores, optional chills, a gating system to feed metal to it, and vents to allow the escape of gas, the mold is ready to be poured.

Another common molding technology used at several of ESCO’s foundries is referred to as “no bake”. In this method the molding sand is mixed with binding agents that harden in a few minutes at room temperature. No flask is necessary to

contain no bake molds.

ESCO uses a wide variety of core-making and mold-making methods and technologies. Our steel foundries are specialized for maximum efficiency. Some of the plants have molding technology that is highly automated while others make castings requiring a great deal of skilled, hands-on labor. Some methods lend themselves to very large castings; others are favored when surface smoothness and dimensional tolerances are critical.

In Portland’s Plant 2 alone four molding methods are used – side floor, pin lift, squeeze and flat top. Next door in Plant 1 there is a unique vacuum molding bay where the mold sand is held in place by the suction formed by a partial vacuum. Plant 3 uses the shell molding process, which has been likened to making

waffles with a hot iron. Newton uses a Herman molding machine to make high volumes of mining teeth and

adapters; and a no-bake line for castings that are too large for the Herman. Port Hope uses K-matic and Kloster semi-automatic molding technology to make industrial castings and ground engaging tools for mining, construction and dredging. Our Guisborough, England foundry has a unique stack molding process suited for making high volumes of points and adapters for construction. ESCO’s foundries Port Coquitlam (BC), Nisku (Alberta), Saskatoon (Saskatchewan), Xuzhou (China) and joint venture SCW (China) all have distinct methods of making molds and cores suited to their product mix. ´

A core box is gently tapped to remove a sand core made on a

Gaylord machine in Portland’s Plant 2


To make steel castings, ESCO starts with scrap steel purchased from reliable local scrap

dealers. The steel must be mild and free of oil, paint or radioactive contamination, preferably in pieces less than two feet across.

Heat Makeup and Melting

by John Howard

A “charge” of steel scrap is dropped into an arc furnace to begin the melting process.


P R O C E S S

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In the “heat makeup” process, the scrap steel is inspected, separated and mixed with foundry returns – scrapped castings and other steel leftovers from the foundry pro-cess. Depending on what castings are being made, alloys such as nickel, molybdenum or silicon are added in mea-sured amounts. From the heat makeup staging area, these calculated “charges” of scrap are transferred to the furnace area for melting. (The price of scrap steel and most alloys has skyrocketed over the last five years.)

ESCO uses two types of furnaces to turn chunks of steel scrap into molten metal. The predominant type is the arc furnace which creates heat with a powerful electric arc. The other is the induction furnace which generates tre-mendous heat by passing electricity through coils.

The larger and more versatile arc furnaces used by ESCO have capacities in the five to 15 ton range. Our smaller foundries operate with a single furnace; a few of our larger foundries utilize two furnaces. Portland, for example, operates a 15-ton and 9-ton furnace simultaneously. Sometimes, the contents of both is needed for a single large casting like a mining bucket lip. A full charge in the 15-ton furnace will take approximately two hours or more to reach “tapping” temperature in excess of 3,200 degrees Fahrenheit.

Samples of molten metal are tested during the melting process for metallurgical content. Spectrometer results let the melting personnel know if additional alloy material must be added to bring the heat up to specification.

In addition to the furnaces, many of ESCO’s foundries have argon-oxygen decarburization (AOD) vessels that are used to further purify the steel. Depending on the alloy and the cast-ings being made, molten metal from the furnace(s) is trans-ferred in ladles by overhead crane to holding ladles or poured into the AOD for refining before it is ready for the molds. ´

Steel scrap and alloys are combined to make “charges” for the furnace

Above right: A powerful crane-mounted magnet is used to make-up charges of scrap steel.

Below right: Tapping an arc furnace.


Pouring and Shakeout

ESCO’s foundries use teapot and bottom-pour ladles suspended from cranes to transfer and

pour molten steel into the molds.

Molten metal is poured into an AOD vessel for purification.Photo by Michael Schultz

by John Howard


P R O C E S S

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Molten metal in excess of 3,200° F is poured into sand molds

The larger bottom-pour ladles can hold up to 40 tons of liquid metal. Most are much smaller. The pouring temperature and technique are critical to obtaining good castings. Ladlemen learn how to release the molten steel at the right, steady speed to avoid imperfections.

Ladles are lined with a dolomite refractory or a synthetic refractory board to prevent the molten metal from touching and destroying the metal skin of the ladle. Ladles are pulled out of service and tested regularly. Furnaces are also inspected, relined and repaired daily.

ESCO Portland has poured castings as heavy as 75,000 pounds by tapping both furnaces and utilizing the capacity

of AOD vessels. Most castings weigh far less. It does not take long for the metal to solidify in smaller molds. Larger castings take longer before they are ready to be separated from the mold.

The process of separating rough castings from their cores and mold sand is called “shakeout”. Most foundries have mechanical means to vibrate the sand off of the still-hot castings. In some cases a mechanical grapple is used to shake and separate castings. The used sand is screened and recycled, while the rough castings are allowed to cool before beginning the finishing process. ´

Red hot ESCO® teeth emerge from shakeout.


Plant 1 (Portland, Oregon, USA)



ESCO Newton (Newton, Mississippi, USA)

ESCO Port Hope (Port Hope, Ontario, Canada)

ESCO Port Coquitlam (Port Coquitlam, BC, Canada)

ESCO Nisku (Nisku, Alberta, Canada)

ESCO Saskatoon (Saskatoon, Saskatchewan, Canada)

ESCO Guisborough (Guisborough, England)

ESCO Xuzhou (Xuzhou, China)

ESCO’S STEEL FOUNDRIESESCO’s Engineered Products operates 10 steel foundries in North America, Europe and Asia. Each has unique capabilities and technologies, and each is focused on particular parts of ESCO’s total product line. By specializing in certain alloys, sizes and product categories, the foundries can operate with great efficiency.

In addition to these 10 ESCO foundries, ESCO products are produced by licensed foundries in Australia (Bradken), Chile (Elecmetal), Japan (Mitsubishi Steel Manufacturing) and South Africa (Scaw Metals). ESCO is also a partner in a joint venture in Taiyuan, China (SCW) and is currently working with licensee Elecmetal to build and operate a joint venture steel foundry in Chile. Here are ESCO’s Engineered Products foundries:

THE EDGE SEPTEMBER 2008 13Foundry photo by Michael Schultz


Finishing

Risers and fins of extra metal are removed from rough castings with a burning torch. Photo by Michael Schultz.

by John Howard


P R O C E S S

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Rough castings go through a number of finishing steps before they are ready to be

shipped or used in a larger assembly like a lip, bucket or dredge cutterhead.


After red-hot castings emerge from shakeout, they are allowed to cool down overnight to the ambient air temperature. Far from pretty, they are still crusted in sand, scale and fins. In most cases, they are also attached to solidified metal sections of the riser and gating system.

Flogging is the process used to separate rough castings from the “risers” and gating system. In the past, most flogging was done manually by sharp blows from a heavy sledge hammer. This labor-intensive method has been largely replaced with more mechanized methods, including the use of crane-mounted hydraulic or pneumatic hammers that jolt and pry the castings apart. In some cases large risers and fins are burned off with a burning torch. Risers, runners, tie bars and other steel pieces salvaged in this process are returned to the heat makeup area and combined with scrap steel and alloys to be melted again.

After the castings are separated from their risers and gating system, they are usually shot blasted to remove sand. Then they are loaded into skips or racks for heat treating. Generally, castings of one alloy are not mixed with castings of a different alloy for heat treating, as each alloy has a specific optimum temperature target. The heat treating process includes both heating and cooling cycles to impart desired mechanical properties to the castings. Batches of castings are placed in gas-fired heat treating ovens and brought to temperatures in excess of 1,700 degrees Fahrenheit. A typical load of castings might remain in the oven for several hours, becoming red hot. When glowing castings are removed from the ovens, they are immediately submerged in circulating water. After water quenching, the castings go into a tempering oven.

The exact temperature, duration, and circulation techniques of heat treating, quenching and tempering can greatly affect the properties, durability and performance of finished castings. ESCO’s heat treating procedures, developed over years of study and experience, are considered valuable trade secrets.

After heat treating, the fins, tie bars, etc., are removed by the “arc air” process where the metal is cut with an electric arc and blown with compressed air. Afterwards, the castings receive a second shot blasting treatment to remove scale from

heat treating and/or slag from the arc air process. The castings are then visually pre-inspected and sorted. Some castings may require weld repair. Others may need grinding with high-speed grinding wheels to remove excess steel from certain surfaces. Gauges are used to test and verify proper dimensions and the fit of all mating castings.

At ESCO, many castings receive Magnaflux inspection, a magnetic particle technique that reveals surface and subsurface flaws under black light. Other inspection technologies include dye penetrant, radiographic (x-ray) and ultrasonic inspection to verify the internal structural integrity of castings. After passing inspection, the castings are counted and logged into Oracle inventory.

The next step in the finishing process is painting. Traditionally, ESCO paints its proprietary earthmoving wear parts green, including points, adapters, shrouds, etc. Structural parts such as lips, buckets, and dredge cutterheads are painted red. In cases where ESCO manufactures parts for original equipment manufacturers (OEMs) we will use their paint color. Over 20 years ago, ESCO switched to a more healthful and environmentally friendly, lead-free, water-based alkyd enamel paint for all castings.

Painted castings are consigned to ESCO’s distribution centers or shipped to OEMs, dealers or end users. Some castings are sent to fabrication facilities such as ESCO’s Covington, Kentucky plant where they are used in the manufacture of buckets, skidder grapplies or other assemblies. ´

Most castings are flogged, heat treated, ground, fit, inspected and painted

ESCO® teeth disappear into a vat ofenvironmentally friendly green paint.



Hank SwigertESCO Corporation Director

INTERVIEW

Henry “Hank” Swigert – grandson of ESCO’s founder – joined the company in 1955. He served as chairman of the board for nearly 25 years before

stepping aside in 2003 to take semi-retirement. As the company’s principal shareholder, he continues to serve as a director and valued advisor to the executive team. He is now 77 years old. This interview with EDGE editor John Howard took place in June, 2008.

Throughout your long career with ESCO – even as chairman of the board – you typically came in and worked a 40 hour week like every other employee. Then, five years ago you stepped aside as chairman and moved out of your ESCO office. I know that you have been missed. How has it been for you to be removed from day-to-day operations at ESCO?

Well, I felt it was very important for me to be physically removed from ESCO. I knew it would be difficult for the people running the company to have an ex-chairman available. I’d been there so long and people were used to coming to me with their questions and problems, so I felt it would be one less distraction for Steve [Pratt] and the others if I moved out.

Do you feel informed?

Oh, yes. My office is just a couple miles from ESCO. Steve, the other board members and the management group have been very good about keeping me informed. I like to keep my finger on the pulse. It is important for me to keep in contact.

So what have you been doing away from ESCO?

Although I’m semi-retired, I like to stay busy. I have personal business affairs and I’m active on the boards of several non-profit organizations, including the World Forestry Center and the Oregon Health & Sciences University Foundation. In addition, there is our Swigert Foundation which is very well managed by Robin Brewer at the Union Bank of California. I’m one of six directors who meet several times a year to try to figure out where our money will do the most good.

In the 1990s, ESCO went through a phase of acquisition and diversification. Then, a couple years ago, the company divested itself of several businesses in order to focus on its Engineered Products and Turbine Technologies businesses. Do you feel this refocusing on key markets and core capabilities has been good for the company?

The board was unanimous in backing management’s suggestion to sell the Industrial Service Centers. We’d been in that business for a very long time, and there were some very valuable and capable employees in that division. We wanted to focus on our core foundry business, while being sensitive to the well-being of those employees. We were fortunate to find Samuel & Son, a private company with a culture akin to ESCO’s. They treat their employees fairly. Samuel & Son has plans to double or triple the business in a short time, so we think it will come out for the best for the former ESCO people who now work for them.

The Integrated Manufacturing business was a different animal. Over the years, ESCO has looked at hundreds of businesses. In the case of the Integrated Manufacturing business, we were eager to get into a high-tech business and participate in the computer age. The companies we bought had unique capabilities and very talented staffs. The cyclical nature of that industry is what hurt us. When the market shifts down, you can get clobbered. So we got out of that business and focused on what we do best.

“In addition to very good people and facilities, I think that having stable ownership

for over 90 years has been important.”


What are ESCO’s strengths?

In addition to very good people and facilities, I think that having stable ownership for over 90 years has been important. It may not sound like a big thing, but companies really suffer when they have to keep adjusting to new bosses and changes in culture. Ownership changes make it difficult to make progress. And local ownership has advantages over being a division of a big corporation.

Another strength has been ESCO’s creativity in employee relations and our consistent history of treating people fairly. It began years ago. In 1919, I think, CF Swigert installed a profit-sharing plan for employees – one of the first of its kind in the western United States. It lasted until the 1960s, when employees voted to exchange it for a funded pension plan. And now we have the employee stock ownership plan. There are not all that many ESOPs around. It is yet another example of ESCO’s innovative approach to employee relations.

Are you satisfied that the ESOP was a good thing for shareholders as well as employees?

Yes, the ESOP should be a strong benefit for our employees depending on how well we all do at managing the company and earning a profit. From the shareholders’ point of view, it allowed the family shareholders to do some estate planning.

How has the recent rise in energy costs affected ESCO?

It isn’t just energy – commodity prices have also risen dramatically. But what is extremely unusual is that the rising prices have occurred during a period of reasonably stable inflation. So far, productivity gains have helped offset rising energy and materials costs.

What are your thoughts on the rise in consciousness about “green” business practices?

Well, as a company we’re dedicated to do what we can to make the planet safer and more livable. But as more and more data comes available, it is prompting discussion and debate about what’s the right course and what is sustainable. ESCO does not have a separate, “sustainability program” because it’s an integral part of the business model we have followed for years - doing more with less, eliminating waste, driving down costs, and empowering employees to pursue continuous improvements. This is ESCO’s culture of lean thinking and practices that we call Quality, Value and Speed (QVS). These business practices lead to sustainable economic, environmental and social benefits.

What do you think of ESCO’s increased direct investment outside the country in recent years – in Mexico, China, Brazil and elsewhere?

We’re very interested in examining every possibility to keep growing, and at present the greatest opportunities for growth are outside North America. I’m delighted to see the percentage of sales from overseas has increased steadily for the last four or five years. It is a wise move at this time for ESCO to develop its presence in those fast-growing markets.

You look very fit. What do you do for fun these days?

I still like skiing in the winter and water sports in the summer – sailing and boating. I haven’t been wind surfing too much recently, but I still love tennis and squash, which I play at least two times a week. The key for me is to do stretching exercises beforehand. You can’t sit around as much as I do, then jump up and start swinging a racquet without warming-up and stretching first.

You’re amazing, Hank, an inspiration to us all. Thank you for sharing your thoughts with readers of the ESCO EDGE.

Henry “Hank” Swigert, grandson of ESCO’s founder, C.F. Swigert


Accomplished industrial photographer Michael Schultz has spent the last three years visiting foundries in the United States and Europe, patiently capturing

the art, power and beauty of this unique industry. He is in the final stages of self-publishing a handsome 176-page book of his photographs, several of which appear in this issue of the EDGE.

“My intent is to give the industry and the public a book which celebrates the spectacular motifs and hard work that happens within foundries,” said the 56-year-old photographer. “I want to honor the industry.” The book titled Foundry Work: A View of the Industry is being printed by Marquand Books of Seattle and will be available in October. It includes a forward written by Raymond Monroe, executive vice president of the Steel Founders Society of America.

Schultz visited ESCO’s Portland foundry in May and spent two days and (tiring) nights taking photographs. Using high-end digital cameras and a tripod for all shots, he preferred shooting during the graveyard shift when there was no ambient daylight to distract from the foundry’s own lighting, sparks and molten metal.

“Everything moves fast in a foundry and you have to know the right camera location beforehand to get the strongest image,” he noted. “That’s why I needed extra time to learn how each operation works.” Schultz had positive things to say about the Portland plant. “ESCO is a first rate company with some great, dedicated people. The facility is well-organized and teamwork is evident everywhere. I would love to come back!”

Mike Schultz has been photographing seriously for over 30 years. His fine art images of industrial processes and architecture have been shown in numerous group and individual exhibitions. His prints appear in several notable museums, corporate board rooms and lobbies.

Ten dramatic images shot at ESCO are included the 10 x 12-inch book – the most of any one foundry. Those wishing to purchase a copy of Foundry Work or learn more about Schultz’s photographic accomplishments may visit www.michaelschultzphotography.com.

Photographer Produces Eye-Catching Tribute to Foundry Industry

© Michael Schultz

Foundry Work: A View of the Industry, by Michael Schultz

by John Howard

ESCO SERVICE ANNIVERSARIES THE EDGE SEPTEMBER 2008 19

David Bell35 • ESCO Port Hope

David was born in Cobourg, Ontario and graduated from Port Hope High School. His first job at ESCO was in grinding and he has also worked in Heat Treat. David is currently an overhead crane operator. He lives in Port Hope with wife Millicent and they have two sons.

Charles Portis40 • ESCO Portland

Charles was born in Calvert, Texas. He graduated from W. D. Spigner High School and attended Prairi View A&M University. Charles worked part-time for the U.S. Post Office before being hired at ESCO in shake-out. He is currently a V-Process molder. Charles and wife Tonya live in N.E. Portland. They have 3 children - Aishash, Quentin, and Ryan - and two grandchildren. When he’s not working, Charles enjoys sports and spending time with his family.

Robert Lovvorn40 • ESCO Portland

Bob was born in Oakland, CA and graduated from David Douglas High School. He served in the United States Navy before being hired at ESCO as a grinder. Bob has also been a furnace operator, crane operator, order filler and garage mechanic. He is currently a facility maintenance driver in the landfill operation. Bob lives in Vancouver and has two children - Carol and Marlene - and four grandchildren. He enjoys old cars and motorcycling when not working.

Lloyd Miller40 • Port Coquitlam

Lloyd was born in New Westminster, BC and graduated from Port Coquitlam Senior Secondary School. He attended UBC before joining ESCO as a cost accounting clerk. Lloyd is currently Purchasing manager. He and wife Heather live in Maple Ridge, BC and have two children - Alycia and Kyla - and one grandchild - Teya. Lloyd enjoys golf, downhill skiing, hiking, reading and woodworking.

Daniel Garlets35 • ESCO Portland

Dan was born in Ritzville, WA. After graduating from high school, he attended a heavy equipment trade school. Before joining ESCO, Dan worked for Union Pacific Railroad, served in the United States Marine Corps, and had a job in a furniture store. He was hired at ESCO as a stand grinder and is currently a painter in Paint and Pack. Dan lives in Portland and when he’s not working he enjoys wood carving, model trains, fishing, and church activities.

Rick Fox35 • ESCO Port Hope

Rick was born in Port Hope, Ontario and graduated from Port Hope High School. He started at ESCO as an arc air welder and has also been a grinder and fab welder. He is currently Inspection team leader. Rick and wife Silvia live in Port Hope. They have four children - Shanna, Cole, Kylen, and Marlaina. His son, Cole, worked in Finishing for the summer. When he’s not working, Rick enjoys playing golf and hockey.

Judy Griffin35 • ESCO Newton

Judy was born in Hattiesburg, MS and graduated from Decatur High School and East Central Community College. Before Judy joined ESCO she was a clerk in the Tax Assessor’s Office. Judy is currently traffic coordinator and lives in Decatur.

David Gibbs35 • ESCO Newton

David was born in Pratt, Kansas and graduated from Lake High School. He started at ESCO as a bucket builder and has also been an assembler in the Fabrication Department. David’s son Justin is also an ESCO employee. David is currently a mechanic in Newton, and lives in Lake, MS with his wife, Carolyn.

Ronald Humphrey35 • ESCO Portland

Ronald was born in Spokane, WA and graduated from Rogers High School. His first job at ESCO was in doghouse. Ronnie has also worked as a crane chaser, in the carpenter shop, in Pouring and Molding. He is currently a machine operator and lives in Forest Grove. Ronnie’s brother, John Veldink, is also an ESCO employee.

Stanley Harris35 • ESCO Newton

Stanley was born in Union, MS and before joining ESCO as a flogger, he worked for Western Auto. He is currently a coremaker at EP Newton. Stanley lives in Collinsville with his wife, Carolyn.

Gerald Leach35 • ESCO Newton

Gerald was born in Newton County, MS and graduated from Union High School. He started at ESCO as a mobile equipment operator and is currently a coremaker. Gerald lives in Union. He has two grown children - Betsy and Robin (a former ESCO scholarship winner).

James Mapp35 • ESCO Newton

James was born in Decatur, MS and graduated from Boler High School. His first job at ESCO was in the Molding Department and he is currently a coremaker. James and his wife, Lue, live in Decatur. They have three grown children - Renae, Derrick and Darrell.

ESCO SERVICE ANNIVERSARIESTHE EDGE SEPTEMBER 200820

James Moudy35 • ESCO Portland

Jim was born in Santa Maria, CA and graduated from Camarillo High School. He worked at another foundry before joining ESCO as a crane chaser. Jim has also worked as a molder, grinder, fitter, and leadman. Currently Jim is a welder in Upper Finishing. He lives in Woodland, WA with wife Ilene. They have two children and four grandchildren. When not working, Jim likes spending time with his family, cooking, and watching a good movie.

Jim Musser35 • ESCO Bucyrus

Jim was born in Bucyrus and graduated from Wynford High School. Before joining ESCO in shear and punch press, Jim worked for a farmer. He is currently a burner operator and trainer in small construction. What Jim likes best about working at ESCO is that the people are great and that he has more overtime than he can handle. Jim and wife Tami live in Bucyrus and have one child. In his free time he enjoys gardening, making home improvements, and working on muscle cars.

Gregory Pollard35 • ESCO Portland

Greg was born in Portland, OR and graduated from Centennial High School. Before joining ESCO in main floor shakeout, Greg was a security officer. He is currently a facility maintenance driver in the landfill operation. Greg and wife Sheila have one son - Jeremy - and two grandchildren - Collin and Gavin. When he’s not working, Greg enjoys gardening and woodworking.

Chris Oldfather35 • ESCO Portland

Chris is Senior Metallurgist in Portland. He was born in Nebraska and graduated from Mentor High School in Mentor, OH. While working on a BS in Metallurgical Engineering at Case Western Reserve University, Chris worked summers for Sandusky Foundry & Machine. ESCO hired him right out of school as a metallurgist. Chris and wife Paula live on a floating home near Scappoose and have one child - Piper. In his free time Chris enjoys bicycling and traveling.

Alan Wilson35 • ESCO Port Hope

Alan is District Manager in Port Hope. He was born in Kirkintilloch, Scotland and emigrated to Canada with his family in 1958. He graduated from Peterborough Collegiate & Vocational School and attended Sir Sandford Fleming as an apprenticeship engineering technician. Alan lives in Port Hope with wife Sheila. They have three daughters and seven grandchildren. Alan plays in the Port Hope Pipe Band and enjoys playing with “The Magnificent Seven” in his free time.

Steven Stone35 • ESCO Portland

Steve was born in La Crosse, WI and graduated from Fort Knox High School. He is a continuous improvement technician in Plant 3. Steve’s sister, Nancy Solomon, also works at ESCO as a Plant 2 core maker. He and wife Suze live in St. Johns and have 5 children and 5 grandchildren. When he’s not working, Steve enjoys carving, making Indian arrow heads, and fishing and hunting at his cabin on the lake in Lakeview.

Craig Martin30 • ESCO Bucyrus

Craig was born in Bucyrus, OH. After graduating from Bucyrus High School, he received a degree in Business Administration from Heidelberg College. Craig is currently District Manager at ESCO Bucyrus. He lives in Bucyrus with wife Cheryl and they have one son - Keith. When he’s not working, Craig enjoys hunting, fishing and reading.

Colleen Charette30 • ESCO Syracuse

Colleen was born in Oneida, NY and started at ESCO right from school, completing her GED through ESCO when it was known as Gray Syracuse. Colleen has worked in die grinding, pre-finish inspection, wax injection and is currently a wax assembler. Her nephew, Kenny Olmsted, also works at ESCO in the foundry. She lives in Chittenango and has two children - James and Robert, who is in the U.S. Army, and three grandchildren. Colleen enjoys reading, camping, and spending time with her grandchildren.

Cindy May30 • ESCO Phoenix

Cindy is Procurement/Materials Manager at ESCO Phoenix. She graduated from Agua Fria Union High School in Avondale, AZ and from Glendale Community College/ASU in General Business. Cindy started at Heflin Steel as a summer job and was hired part-time at the end of the summer as she continued college. Cindy and husband Roy live in Chandler, AZ and have four children and two grandchildren. In her free time she likes spending time with family, shopping, swimming, camping, and traveling.

Marybeth Rodgers30 • ESCO Port Coquitlam

Marybeth was born in Chilliwack, BC and graduated from Centennial Senior Secondary School. She started at ESCO as a file clerk and also worked in inventory and inside sales. Marybeth is currently a buyer. She lives in Coquitlam with her teenage daughter, Kelsey. Marybeth says Kelsey likes to ride horses and that keeps both of them very busy in their free time.

Blake Mousley30 • ESCO West Jordan

Blake is Production Supervisor in West Jordan. He was born in Murray, UT and graduated from Bingham High School. Blake attended Southern Utah University and worked for Keddmac Welding before joining ESCO. What he likes best about ESCO is: “working with a lot of fun people.” Blake lives in Riverton and has two children - Mallorie and Colton. When not working he likes camping, working in the yard, golfing, four-wheeling, and spending time with family and friends.

William Schatz30 • ESCO Portland

Bill was born in Danville, IL and graduated from Danville High School. He has a B.S. in Business with a focus on Production Management from Eastern Illinois University. Bill’s first job at ESCO was Inside Sales with ESCO in Danville. He is currently Senior Account Manager - Industrial Products Division. He and wife Janet live in NW Portland and have three children - Katie (who also works at ESCO in HR), Michael, and Laura. Bill enjoys traveling and sports (“anything with a ball”).

ESCO SERVICE ANNIVERSARIES THE EDGE SEPTEMBER 2008 21

Leonard Smith30 • ESCO Newton

Leonard graduated from Decatur High School. Before joining ESCO as a grinder, he was in the National Guard for 8 years and worked for the highway department. Leonard has also worked as a bucket builder and is currently an inspector in Newton. He and his wife, Sandra, live in Decatur. They have two sons – Kalvin and Justin.

Michael Whited30 • ESCO Bucyrus

Mike was born in Bucyrus, OH and graduated from Bucyrus High School. Mike was first hired at ESCO as a punch helper and he is currently a plate cell burn operator. He says what he likes best about working at ESCO are “the people.” Mike lives in Bucyrus and when he is not working he enjoys riding his motorcycle and golfing.

William Blything25 • ESCO Cleveland

Bill was born in East Cleveland, OH and graduated from Collinwood High School. He has an Associate of Allied Business from Lakeland Community College. Bill is currently a customer service representative. Other family members who also work at ESCO are wife Lisa in Engineering, daughters Jennifer and Jessica in Finishing and Shipping, and brother Dennis in Core. He and Lisa live in Mentor, and Bill enjoys sports and going to the movies when not working.

James Broach25 • ESCO Newton

James was born in Hickory, MS and is a molding leadman at EP Newton. Before joining ESCO as a painter in Maintenance, James worked on a dairy farm. He has also worked as a close-up operator in molding and as a coresetter. He and his wife Christian have six sons and live in Hickory, MS.

William Kirgis25 • ESCO Bucyrus

Bill was born in Bucyrus, OH and graduated from Tiffin Columbian High School. Before joining ESCO he worked at Timken and is currently in commodity cell. Bill’s brother-in-law, Mark Fox, is also an ESCO employee. Bill and wife Joan live in Bloomville and have four children. He likes gardening, working with wood, working in the yard, and spending time with his family.

Kerry Morley25 • ESCO West Jordan

Kerry was born in Odgen, Utah. After graduating from high school he attended Weber State University. He worked in the lumber business and served in the U.S. Air Force before starting at ESCO as a painter. Kerry is currently the Shipping manager and says he likes the new Oracle and Lean Process at ESCO. He lives in West Jordan with wife Anne. They have one daughter - Rebecca - and seven grandchildren. In his free time Kerry enjoys going to his cabin, traveling, and raising his poodles.

Wendell Thorne25 • ESCO Newon

Wendell is currently a mobile equipment operator in maintenance. Before he joined ESCO, Wendell worked for an auto body shop and a local furniture manufacturer. He started at ESCO as a flogger and has also worked as a shake out operator. Wendell and his wife Vicky live in Conehatta, MS.

Brenda Antonacci25 • ESCO Cleveland

Brenda was born in Willoughby, OH, graduated from Mentor High School and attended Lakeland Community College. Before joining ESCO in wax assembly, Brenda worked in a flower shop as a floral designer. She is currently a DS engineering technician. Brenda’s husband, Dennis Antonacci, works at ESCO in the metallurgical lab and her mother, Elsi Tye, works in wax assembly. Brenda and Dennis live in Eastlake, OH. Brenda enjoys gardening, playing the slot machines and watching TV in her free time.

Mickey Bloomfield20 • ESCO Bucyrus

Mickey was born in Camp Dix, KY and graduated from Wynford High School. He started at ESCO as a punch operator and is currently a press operator. Mickey lives in Marion with wife Tami and they have three children and one grandchild. When he’s not working, Mickey enjoys playing music and spending time with his family.

Jeffrey Bogard20 • ESCO Bucyrus

Jeff was born in Bucyrus, OH and graduated from Wynford High School. Before joining ESCO, he was a meatcutter at Geyer’s. Jeff started working at ESCO as a burner operator, and feels ESCO is a nice place to work. Jeff is currently in maintenance. He lives in rural Bucyrus with wife Paula and they have three children - Nathan, Jessica, and Travis. When he’s not working, Jeff enjoys farming, hunting and fishing.

Keith Brown20 • ESCO Bucyrus

Keith is currently a mill operator in Bucyrus. He was born in Toledo, OH and attended Genoa High School. Before joining ESCO as a punch operator he worked in landscaping. Keith’s son-in-law, Dana Sutton, also works at ESCO in the small construction area. Keith and wife Shirley live in Bucyrus and have two children - Cynthia and Ashley - and two grandchildren. When he’s not working Keith enjoys playing golf and going to church.

Mary Dudash20 • ESCO Cleveland

Mary was born in Painesville, OH and graduated from Willoughby South High School. Mary worked for a dry cleaners before joining ESCO as a finisher, and is currently an FPI reworker. Her niece, Becky Pastor, also works for ESCO in quality. Mary lives in Painesville Township and has one son - Christopher. When she’s not working, Mary enjoys walking, reading a good book, playing Bingo, and spending time with family and friends.

ESCO SERVICE ANNIVERSARIESTHE EDGE SEPTEMBER 200822

Ronald Schultz20 • ESCO Cleveland

Ron was born in Cleveland, OH and graduated from Mentor High School. Before joining ESCO, Ron worked at The Ground Round Restaurant. He was hired at ESCO as a sandblaster and is currently a dimensional inspector. He lives in Willoughby with wife Darlene. When he is not working he enjoys riding motorcycles, working with computers, going to the movies, and hanging out with family and friends.

George Ewing20 • ESCO Bucyrus

George was born in Crestline, OH and graduated from Galion High School. He attended North Central Technical College in Ohio before entering the United States Air Force. When George started at ESCO, he was a shear and punch operator and is currently an induction and mill operator. He and partner Lori LaChance live in Crestline. When not working, George likes golfing, fishing, target shooting, and playing pool.

Mark Garverick20 • ESCO Bucyrus

Mark was born in Galion, OH and graduated from Colonel Crawford High School. Before Mark joined ESCO in punch press, he worked in farming. He says what he likes best about working at ESCO are the people. Mark lives in Galion, OH with wife Nichole. They have three children - Nick, Nickyla, and Marcus. In his free time, Mark enjoys watching his childrens’ sports and riding his Harley.

Ronald Grill20 • ESCO Port Coquitlam

Ron was born in New Westminster, BC and graduated from Terry Fox High School. Hewas hired at ESCO as a molder helper and is currently a molder/sprayer. Family members also at ESCO are cousin Jamie Geill (crane) and brother-in-law Pat Newbery (coreroom). He has two children - Trevor and Brittany. In his free time, Ron enjoys hockey, traveling and going to the gym.

Brent Hoffman20 • ESCO Bucyrus

Brent was born in Bucyrus, OH and graduated from Wynford High School. He was hired at ESCO as a punch operator and currently works in the Shipping/Paint Department. Brent lives in Bucyrus with his wife of 27 years, Brenda. They have four children - Elizabeth, Christopher, Missi, and Daniel. When he’s not working, Brent likes cutting firewood, bow hunting, fishing, and traveling through the beautiful U.S.A.

Daren Knight20 • ESCO Port Coquitlam

Daren was born in Edson, Albert and graduated from Terry Fox Senior Secondary School. He joined ESCO as a molder and currently works in Pattern and Storage. Three of Daren’s cousins also work at ESCO - Tiffany Watts, Adam Watts and Richard Burdett. Daren and wife Jennifer live in Port Coquitlam and have two children - Jake and Sidney. When he’s not working, Daren enjoys golfing and playing baseball.

Carol Lambert20 • ESCO Cleveland

Carol was born in Biddeford, ME and graduated from St. Andre High School. Before she joined ESCO in Visual Inspection, Carol worked for Fairchild Semiconductor. She is currently a DS wax dresser. Carol and husband Dennis live in Willowick. When she’s not working, Carol likes bargain hunting and watching sunsets over the lake.

Bryan Linde20 • ESCO Port Coquitlam

Bryan was born in Maple Ridge, BC and graduated from Pitt Meadows Secondary School. He joined ESCO as a molder and is currently a fabricator. What he likes best about working at ESCO are the friends he has made over the years. His father, Hillar Linde, is an ESCO retiree. Bryan lives in Maple Ridge with wife Pamela. They have two children - Elyssa and Kiana. When he’s not working, Bryan enjoys fishing and playing volleyball.

Douglas Minard20 • ESCO Portland

Doug was born in Portland, OR and graduated from Jefferson High School. Before joining ESCO as a flogger, he worked in Forestry Service. Doug is currently an inspector in LFA. His father, Bill Minard, also works at ESCO in Maintenance. What he likes best about working at ESCO is “everyone working as a team.” Doug lives in NE Portland and when he’s not working he enjoys music, playing drums, bicycling, and working on art projects.

Mario Piluso20 • ESCO Port Coquitlam

Mario was born in Quebec and graduated from Vancouver Technical School. He started at ESCO in Molding and is currently in Pattern and Storage. Mario’s father-in-law, Romano Bigiolli, is an ESCO retiree. Mario and wife Doris live in Maple Ridge and have two children - Michael and Paul. When he’s not working, Mario likes watching his kids play ice hockey and ball hockey.

Rubin Schroeder20 • ESCO Steinbach

Rubin was born in Paraguay, South America and attended Steinbach Junior High School. Rubin worked in construction before being hired by ESCO as a punch/press operator and is currently the Maintenance team leader. He says he likes the “friendly people and clean safe work environment” at ESCO. He lives in Steinbach with wife Susan and they have four children. When he’s not working he enjoys spending time with family and friends.

John McMurria40 years

ESCO Portland

Dave Ellas25 years

ESCO DM (Seattle)

Not Pictured

Robert Smith20 • ESCO Port Coquitlam

Robert graduated from Gladstone Secondary School and before joining ESCO he worked for Reay’s Moving & Storage. Robert’s first job at ESCO was in clamps and wedges and he is currently a mobile operator. His brother-in-law, Bill Ashbury, is also an ESCO employee. Robert lives in Port Coquitlam with wife Diane and they have two children - John and Leanne. When not working, Robert enjoys spending time on his art work.

Mike Starosciak20 • ESCO Portland

Mike was born in Portland, OR and graduated from Adams High School, The University of Washington and Oregon Graduate Institute. Prior to working at ESCO he was an auto mechanic and served four years in the United States Air Force as a crew chief. Mike is currently lead engineer, Dredge Products. He likes the fact that ESCO still thinks of itself as a small family-run company. Mike lives in Portland with wife Janet, and in his free time enjoys music, church, and golf.


ORGANIZATIONAL CHANGES

Steve Herbert NamedBusiness Manager, Mining and Industrial Products

Aaron Lian Named Managing Director, ESCO Europe

Jim Liberator NamedVice President, SalesTurbine Technologies Group

Sinha Priyabrata NamedChief Representative, ESCO Liaison office Kolkata, India

Randy Jones Named Sales Manager, Midwest Region

ESCO CORPORATION

2141 NW 25th Avenue

Portland, Oregon 97210-2578

United States of America

PRESORTED STANDARD

US POSTAGE

PAID

Portland, Oregon

Permit No. 382

In an upcoming issue of the EDGE – A review of ESCO’s robust dredge products business. Photo by Ruud Koers.

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