Case studies

Relevant service: Business Transformation, Operational Excellence

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Supporting the Intercast & Forge ‘New Ways of Working’

About the Company

Since 1946, Intercast & Forge has continually made improvements to become a world leader in applying innovation and technology to iron castings. They have consistently set the benchmark for demonstrating what is possible and how innovative thinking leads to greater production and product performance.

The Challenge

Support the organisation's business transformation by building Leadership & Lean capability.

Company

Intercast & Forge

Industry

Manufacturing, Process Industry

Size

170 Employees

Revenue

AUS $ 69.82 million

What We Did

To support the transformation at Intercast & Forge we:

Took the Leadership team through the Lean Leadership program ensuring they had the capability and confidence to drive continuous improvement at a systems level.
We supported the development of Lean Practitioners across the organisation ensuring they developed an understanding of lean principles and problem solving skills.
All employees completed the Lean Awareness training accredited by LCS and Cardiff University.
Developed new 'Ways of Working' built around 'Ideal Behaviours'

"The introduction of Lean has contributed to major successes within Pandrol Australia and Intercast & Forge by the successful cost reductions through elimination of unnecessary activities, reduction in inventory and reduction in scrap. Most importantly lean has made a significant contribution to raise productivity which has led to improved customer service."

Pierre Barthram

Results

The program is credited with supporting the organisation move from a position of $1m a year in scrap to under $90k per annum

Working inventory was reduced by over $1 million.

From an operations perspective:

A greater awareness of customer needs and standards
Improved relationship with core customers
Engaged workforce in change initiatives

Framework

Operational Excellence

Academy - Lean Skills

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