ABN 93 107 043 201

LeanCast Pty. Ltd. – Capability Statement

LeanCast Pty.Ltd. is a new company in the Aluminium Industry. It has been formed to bring together a team of technical, engineering and management professionals with equipment vendors that specialise in casthouses, and particularly ingot casting. Although by definition a consulting firm, we offer much more than advice, training and reports. Our focus is on YOUR OUTPUTS, and we have the technology, the experience and the commitment to give you the best possible performance. Our Areas of Work / Technologies include:

INGOT CASTHOUSE DESIGN

· Utilise the latest in technology and casthouse design thinking,

· Capital savings of 15% and operating cost savings of 10% are achievable over current benchmarks

· Access to a team that has a proven track record with the technology and has proven ingot casthouse results.

Although the outcomes are best in greenfield design, many casthouses can obtain significant benefits through upgrade engineering.

CASTHOUSE CONSTRUCTION and PROJECT MANAGEMENT

· We have a track record in 3 ingot casthouse construction projects and on one significant upgrade project, with involvement in design, project management, commissioning and operations.

· We not only have a successful track record, but have learned the lessons that will make your project a success.

· Our experience and knowledge of the vendors and technology will ensure your project is delivered on time, achieving the planned savings and will perform correctly from the start.

· In ingot casting, historically, significant costs are normally incurred in re-engineering. We will deliver the best from the start.

EQUIPMENT COMMISSIONING

Our team has been involved in the commissioning of 6 new ingot lines over the past 5 years. We have first hand experience of all the major vendors and their equipment. This will help you deliver the right performance from your equipment. Using a rigorous approach to commissioning, it is possible to ensure that not only the performance is correct, but the equipment is safe, reliable, and that the operating procedures, systems and first wave of training is right for the operations team.

OPERATION TEAM DEVELOPMENT / MANAGEMENT / TRAINING

Building an operations team can be a challenge. Ingot casting is at its heart a simple process, however it remains relatively labour intensive. The need to build a team, the right culture and to make sure that safety is correct, right from the beginning needs a huge investement of specialist support at an early stage. After a short period of time, this expertise is no longer needed. By contracting in all or part of this expertise, your organisation can obtain all the desired results, without burdening your organisation in the longer term with large numbers of ‘expensive’ experts. We have access to a wide range of expertise in all aspects of establishing an operations organisation, and can assist you, or manage the enire job for you.

TECHNOLOGY DELIVERY

Members of our team have worked with the development of many critical technologies for the casthouse. Until now, most of these are not commercially available:

· Ingot Height Control (reduce scrap levels by half, and improve bundle build quality and transportability)

· Siphoning (reducing melt loss from 1% down to figures approaching 0.4%)

· Machine Reliability Improvement (delivering non-stop, hands free operation)

· Operations Management Software (building software with excellent usability and integration)

We are prepared to handle large and small projects.

OPERATIONAL AUDITS

We are in a position to complete audits of casthouse performance, utilising our most experienced people. We provide an assessment of your ingot casthouse in all areas, from technology, to safety, to management systems and organisation. These are cost effective and provide an excellent means to benchmark your organisation, allowing the participation of your entire team, not just one or two sent on a trip.

COMMERCIAL FLEXIBILITY

With our hands on approach, we can bring a different approach to your project. If capital availability or ROI is a barrier, leasing of equipment is an option that can be explored. There are a number of engineering firms and finance suppliers who are very interested in leasing or BOO arrangements. Alternatively LeanCast can run the entire operation for you. Ask yourself the question, is the ingot casthouse a core part of your business?

PARTNERS

Technology development, implementation, project management and commissioning are never done in isolation. We have good working relationships extending over many years with the key suppliers to the industry. We also have access to a number of contractors and technology specialists with whom we have been doing joint technology development.

We work with these suppliers, taking time to review not only overall design, but the details, and most importantly, making sure that all the pieces fit together in concert.

CONTACT

Current Base: Australia

Phone: + 61 (401) 825 445

Email: info@leancast.com

The Partner to deliver value in your Ingot Casthouse