Emerson Automation Solutions – Appleton Group 

Moving forward with shared vision

Thursday, Nov. 7 Location Code
7:00am-1:30pm ThT/02

No jewelry may be worn on this tour (watches, rings, necklaces, bracelets, etc.)

Hard hats and shop coats will be provided.

Emerson’s South Milwaukee foundry produces 15 million castings annually (1,500 SKUs) in its 150,000 sq ft, facility. Vertical and horizontal green sand molding machines, with finishing and annealing capabilities, produce gray and ductile iron castings ranging from a few ounces to 35 lbs, mainly for internal use. Perfect Execution (Lean Manufacturing) has played a major part in transforming the South Milwaukee foundry from a facility on the brink of extinction, after a fire in 2010, to the facility that, in 2018, won a top award from the foundry industry. South Milwaukee has improved its recordable incidents (5 to 1.95), TRR (4 to 1.9) and TLRR (3 to 1.58) safety rates over the last 4 years through various programs aimed at improving the overall safety culture. The internal scrap rate was reduced from 10% to 2.5%, and returns were reduced from 5% down to 0.8%, over a 7-year period, through pattern improvements, AQL inspections and other initiatives. Internal lead times have been reduced from 25 days to 8 days, through a series of improvement initiatives. On-time delivery has improved from 66% to 99% over the same period, which has led to improved inventory turns, from 25.5 to 50.4, through more management focus and improved equipment reliability.


Emerson’s teams across the world are constantly striving to be more connected, forward-looking and customer-focused. The company’s values serve as its foundation, informing every decision. This shared vision keeps Emerson grounded as a company, moving forward together even as the industries it serves continue to shift and transform. Emerson’s new technology and engineering-based program combines industry expertise, consulting services, comprehensive automation technologies, and new Industrial IoT solutions to achieve top quartile performance in the areas of safety, reliability, production and energy management. www.emerson.com

Restrictions / Requirements

To participate in a tour, all attendees must adhere to and respect the tour hosts' restrictions and requirements.
Non-adherence may exclude you from a tour.

  • No cell phones
  • No recording devices
  • Other: See tour description
  • Hearing protection
  • Leather like closed-toe shoes (No high heels)
  • Long or short-sleeved shirt/blouse
  • Long pants (no shorts, skirts, dresses)
  • Other: See tour description
  • Safety glasses
  • Steel-toed shoes