{"id":3712,"date":"2021-09-09T10:35:34","date_gmt":"2021-09-09T10:35:34","guid":{"rendered":"https:\/\/beta.twivietnam.vn\/?p=3712"},"modified":"2026-05-12T14:53:09","modified_gmt":"2026-05-12T14:53:09","slug":"esco-success-story","status":"publish","type":"post","link":"https:\/\/twivietnam.vn\/en\/esco-success-story\/","title":{"rendered":"ESCO Success Story"},"content":{"rendered":"<div class=\"fusion-fullwidth fullwidth-box fusion-builder-row-1 fusion-flex-container nonhundred-percent-fullwidth non-hundred-percent-height-scrolling\" style=\"--awb-border-radius-top-left:0px;--awb-border-radius-top-right:0px;--awb-border-radius-bottom-right:0px;--awb-border-radius-bottom-left:0px;--awb-padding-right:0px;--awb-padding-left:0px;--awb-flex-wrap:wrap;\" ><div class=\"fusion-builder-row fusion-row fusion-flex-align-items-flex-start fusion-flex-content-wrap\" style=\"max-width:1248px;margin-left: calc(-4% \/ 2 );margin-right: calc(-4% \/ 2 );\"><div class=\"fusion-layout-column fusion_builder_column fusion-builder-column-0 fusion_builder_column_1_1 1_1 fusion-flex-column\" style=\"--awb-bg-size:cover;--awb-width-large:100%;--awb-margin-top-large:0px;--awb-spacing-right-large:1.92%;--awb-margin-bottom-large:20px;--awb-spacing-left-large:1.92%;--awb-width-medium:100%;--awb-order-medium:0;--awb-spacing-right-medium:1.92%;--awb-spacing-left-medium:1.92%;--awb-width-small:100%;--awb-order-small:0;--awb-spacing-right-small:1.92%;--awb-spacing-left-small:1.92%;\"><div class=\"fusion-column-wrapper fusion-column-has-shadow fusion-flex-justify-content-flex-start fusion-content-layout-column\"><\/div><\/div><div class=\"fusion-layout-column fusion_builder_column fusion-builder-column-1 fusion_builder_column_1_1 1_1 fusion-flex-column\" style=\"--awb-bg-blend:overlay;--awb-bg-size:cover;--awb-width-large:100%;--awb-margin-top-large:0px;--awb-spacing-right-large:1.92%;--awb-margin-bottom-large:0px;--awb-spacing-left-large:1.92%;--awb-width-medium:100%;--awb-spacing-right-medium:1.92%;--awb-spacing-left-medium:1.92%;--awb-width-small:100%;--awb-spacing-right-small:1.92%;--awb-spacing-left-small:1.92%;\"><div class=\"fusion-column-wrapper fusion-flex-justify-content-flex-start fusion-content-layout-column\"><div class=\"fusion-text fusion-text-1\"><p style=\"color: var(--awb-custom_color_6);\"><i><b style=\"color: var(--awb-color7);\">ESCO Turbine Technologies | Success case stories<\/b><\/i><\/p>\n<\/div><div class=\"fusion-text fusion-text-2\"><p style=\"text-align: justify;\">ESCO Turbine Technologies<span style=\"font-weight: 400;\"> (formerly a division of ESCO Corporation) was a <\/span><span style=\"font-weight: 400;\">manufacturer of precision investment-cast components for the aerospace, energy, and industrial markets<\/span><span style=\"font-weight: 400;\">. Specializing in complex superalloy castings, they produced crucial turbine parts before being acquired by Consolidated Precision Products (CPP).<\/span><\/p>\n<p style=\"text-align: justify;\"><span style=\"font-weight: 400;\">The <\/span><b>ESCO Turbine Technologies (Syracuse, NY)<\/b><span style=\"font-weight: 400;\"> case study is a prominent example of how <\/span><b>Training Within Industry (TWI)<\/b><span style=\"font-weight: 400;\">\u2014specifically the <\/span><b>Job Instruction (JI)<\/b><span style=\"font-weight: 400;\"> module\u2014can be used to solve critical production and quality issues in high-precision manufacturing.<\/span><\/p>\n<\/div><\/div><\/div><div class=\"fusion-layout-column fusion_builder_column fusion-builder-column-2 fusion_builder_column_1_1 1_1 fusion-flex-column\" style=\"--awb-bg-color:var(--awb-custom_color_5);--awb-bg-color-hover:var(--awb-custom_color_5);--awb-bg-size:cover;--awb-width-large:100%;--awb-margin-top-large:10px;--awb-spacing-right-large:0.384%;--awb-margin-bottom-large:0px;--awb-spacing-left-large:0.384%;--awb-width-medium:100%;--awb-order-medium:0;--awb-spacing-right-medium:0.384%;--awb-spacing-left-medium:0.384%;--awb-width-small:100%;--awb-order-small:0;--awb-spacing-right-small:1.92%;--awb-spacing-left-small:1.92%;\"><div class=\"fusion-column-wrapper fusion-column-has-shadow fusion-flex-justify-content-flex-start fusion-content-layout-column\"><div class=\"fusion-text fusion-text-3\"><p style=\"text-align: center;\"><b style=\"color: var(--awb-custom_color_6);\">Core Problem: The &#8220;Nozzle&#8221; Issue<\/b><\/p>\n<p style=\"text-align: left;\"><span style=\"font-weight: 400;\">The facility, which specializes in investment casting for aerospace and power generation turbines, faced a significant quality crisis involving a specific <\/span><b>turbine <\/b><span style=\"margin: 0px; padding: 0px;\"><strong>nozzle <\/strong>part<\/span><span style=\"font-weight: 400;\">. <\/span><\/p>\n<ul>\n<li style=\"text-align: left; font-weight: 400;\" aria-level=\"1\"><b>High Defect Rate:<\/b><span style=\"font-weight: 400;\"> One particular part had a staggering <\/span><b>84% scrap\/rework rate<\/b><span style=\"font-weight: 400;\">, meaning only 16% of parts were made correctly on the first attempt.<\/span><\/li>\n<li style=\"text-align: justify; font-weight: 400;\" aria-level=\"1\"><b>Skill Gaps:<\/b><span style=\"font-weight: 400;\"> Experienced operators were retiring, and the training of new staff was inconsistent, leading to &#8220;tribal knowledge&#8221; where everyone performed the job differently.<\/span><\/li>\n<\/ul>\n<\/div><\/div><\/div><div class=\"fusion-layout-column fusion_builder_column fusion-builder-column-3 fusion_builder_column_1_1 1_1 fusion-flex-column\" style=\"--awb-bg-size:cover;--awb-width-large:100%;--awb-margin-top-large:0px;--awb-spacing-right-large:0%;--awb-margin-bottom-large:0px;--awb-spacing-left-large:0%;--awb-width-medium:100%;--awb-order-medium:0;--awb-spacing-right-medium:0%;--awb-spacing-left-medium:0%;--awb-width-small:100%;--awb-order-small:0;--awb-spacing-right-small:1.92%;--awb-spacing-left-small:1.92%;\"><div class=\"fusion-column-wrapper fusion-column-has-shadow fusion-flex-justify-content-flex-start fusion-content-layout-column\"><div class=\"fusion-text fusion-text-4\"><p style=\"text-align: center;\"><b style=\"color: var(--awb-custom_color_6);\">TWI Implementation &amp; Results<\/b><\/p>\n<p style=\"text-align: center;\"><span style=\"font-weight: 400;\">Using the <\/span><b>JI (Job Instruction)<\/b><span style=\"font-weight: 400;\"> method, the company standardized the &#8220;best way&#8221; to perform the complex casting and finishing tasks.<\/span><\/p>\n<\/div><div class=\"fusion-image-element \" style=\"--awb-caption-title-font-family:var(--h2_typography-font-family);--awb-caption-title-font-weight:var(--h2_typography-font-weight);--awb-caption-title-font-style:var(--h2_typography-font-style);--awb-caption-title-size:var(--h2_typography-font-size);--awb-caption-title-transform:var(--h2_typography-text-transform);--awb-caption-title-line-height:var(--h2_typography-line-height);--awb-caption-title-letter-spacing:var(--h2_typography-letter-spacing);\"><span class=\" fusion-imageframe imageframe-none imageframe-1 hover-type-none\"><img decoding=\"async\" width=\"1858\" height=\"481\" title=\"edit &#8211; 2026-05-05T185520.539\" src=\"https:\/\/twivietnam.vn\/en\/wp-content\/uploads\/2026\/05\/edit-2026-05-05T185520.539.jpg\" alt class=\"img-responsive wp-image-4594\" srcset=\"https:\/\/twivietnam.vn\/en\/wp-content\/uploads\/2026\/05\/edit-2026-05-05T185520.539-200x52.jpg 200w, https:\/\/twivietnam.vn\/en\/wp-content\/uploads\/2026\/05\/edit-2026-05-05T185520.539-400x104.jpg 400w, https:\/\/twivietnam.vn\/en\/wp-content\/uploads\/2026\/05\/edit-2026-05-05T185520.539-600x155.jpg 600w, https:\/\/twivietnam.vn\/en\/wp-content\/uploads\/2026\/05\/edit-2026-05-05T185520.539-800x207.jpg 800w, https:\/\/twivietnam.vn\/en\/wp-content\/uploads\/2026\/05\/edit-2026-05-05T185520.539-1200x311.jpg 1200w, https:\/\/twivietnam.vn\/en\/wp-content\/uploads\/2026\/05\/edit-2026-05-05T185520.539.jpg 1858w\" sizes=\"(max-width: 640px) 100vw, 1858px\" \/><\/span><\/div><div class=\"fusion-text fusion-text-5\" style=\"--awb-font-size:16px;\"><p><b>Key Takeaways from the Study<\/b><\/p>\n<ol>\n<li style=\"text-align: justify; font-weight: 400;\" aria-level=\"1\"><b>Job Instruction Breakdowns:<\/b><span style=\"font-weight: 400;\"> Supervisors identified &#8220;Key Points&#8221;\u2014the small &#8220;knacks&#8221; or safety tricks that make or break a task\u2014and incorporated them into formal training.<\/span><\/li>\n<li style=\"text-align: justify; font-weight: 400;\" aria-level=\"1\"><b>Supervisor as Trainer:<\/b><span style=\"font-weight: 400;\"> Instead of HR or outside consultants, the shop floor supervisors became the primary teachers, ensuring the training was practical and respected.<\/span><\/li>\n<li style=\"text-align: justify; font-weight: 400;\" aria-level=\"1\"><b>Foundation for Lean:<\/b> This success helped ESCO establish a foundation for more advanced Lean manufacturing techniques by first stabilizing their processes.<\/li>\n<\/ol>\n<\/div><div ><a class=\"fusion-button button-flat fusion-button-default-size button-custom fusion-button-default button-1 fusion-button-default-span fusion-button-default-type\" style=\"--button_accent_color:var(--awb-custom_color_6);--button_border_color:var(--awb-custom_color_6);--button_accent_hover_color:var(--awb-color1);--button_border_hover_color:var(--awb-color1);--button-border-radius-top-left:44px;--button-border-radius-top-right:44px;--button-border-radius-bottom-right:44px;--button-border-radius-bottom-left:44px;--button_gradient_top_color:var(--awb-color1);--button_gradient_bottom_color:var(--awb-color1);--button_gradient_top_color_hover:hsla(var(--awb-color5-h),calc(var(--awb-color5-s) - 5%),calc(var(--awb-color5-l) - 10%),var(--awb-color5-a));--button_gradient_bottom_color_hover:hsla(var(--awb-color5-h),calc(var(--awb-color5-s) - 5%),calc(var(--awb-color5-l) - 10%),var(--awb-color5-a));\" target=\"_blank\" rel=\"noopener noreferrer\" download href=\"https:\/\/twivietnam.vn\/en\/wp-content\/uploads\/2026\/05\/CaseStudy_ESCO_TWI.pdf\"><span class=\"fusion-button-text\">Read more about this case study<\/span><i class=\"fa-angle-double-right fas button-icon-right\" aria-hidden=\"true\"><\/i><\/a><\/div><div class=\"fusion-text fusion-text-6\" style=\"--awb-font-size:14px;--awb-line-height:1;--awb-margin-top:20px;\"><p style=\"text-align: justify;\"><i><span style=\"font-weight: 400;\">Note: In late 2012, ESCO Corp. sold its Turbine Technologies division (which included the Syracuse and Concorde Castings facilities) to the newly formed Consolidated Precision Products (CPP). <\/span><\/i><i><span style=\"font-weight: 400;\">But the case study remains a staple in <\/span><\/i><span style=\"color: #0000ff;\"><i><span style=\"font-weight: 400;\">TWI Institute<\/span><\/i><\/span><i><span style=\"font-weight: 400;\"> curricula for showing how the 1940s-era TWI program still works in modern high-tech environments<\/span><\/i><\/p>\n<\/div><\/div><\/div><\/div><\/div>\n","protected":false},"excerpt":{"rendered":"","protected":false},"author":3,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[1],"tags":[49,51,44,42],"class_list":["post-3712","post","type-post","status-publish","format-standard","hentry","category-news-insights","tag-manufacturing","tag-performance","tag-trainingwithinindustry","tag-twi"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v22.6 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>ESCO Success Story - TWI VIETNAM<\/title>\n<meta name=\"robots\" content=\"noindex, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"ESCO Success Story - 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