Efficiency as a Mindset
At Lestercast, production efficiency isn’t a one-off project—it’s a mindset embedded into every aspect of our operations. Producing over one million castings annually across more than twenty industries worldwide requires more than just robust equipment; it demands strategic planning, empowered people, and an unwavering commitment to continuous improvement.
As Production Manager Craig Townsend explains, our focus is simple: deliver quality, consistency, and sustainability—without compromise. Here’s a closer look at the key areas we’re optimising to make that happen:
CRAIG TOWNSEND – PRODUCTION MANAGER
Energy Consumption & Sustainability
With rising energy costs, reducing consumption is critical. We actively track departmental usage, invest in energy-efficient equipment, and promote best practices across all shifts. This not only cuts operational costs but supports our sustainability goals—a priority that’s central to how we do business.
Factory Efficiency & Layout
Our factory operates on lean manufacturing principles, with an optimised layout designed for maximum throughput. From production line planning to streamlined workflows, every inch of our facility supports high-capacity output with minimal waste or delay.
On-Time Delivery (OTD)
We’re proud to be operating at 93% on-time delivery and are firmly on track to meet our annual target. Synchro ERP plays a pivotal role in helping us schedule efficiently and make real-time, data-driven decisions. A key initiative right now is on improving our Rapid Prototyping delivery speed and efficiency, we are aiming to shorten lead times and get parts into customers hands faster than ever, without compromising on quality. Expect to see more on this topic later this year.
Product Quality & Defect Reduction
Quality isn’t just a final checkpoint—it’s built into every stage of our process. We’re accredited to ISO 9001 and the automotive specification IATF 16949, and each department leader is accountable for quality at their stage of production. Weekly scrap meetings help us pinpoint root causes and make fast, effective improvements. The result? High-integrity castings, reduced waste, and satisfied customers.
Upskilling the Workforce
As one of the few investment casting foundries in the UK, we take pride in developing our team internally. Every operator is trained on multiple machines, increasing flexibility and productivity. We also invest heavily in cross-departmental training, which reduces downtime and creates a more dynamic workforce. Health & Safety is embedded in this training—ensuring both performance and protection.
Preventative Maintenance
Downtime is the enemy of efficiency. Through Limble, our digital maintenance platform, we’ve strengthened our preventative maintenance schedule. This proactive approach minimises breakdowns, boosts machine lifespan, and keeps our delivery promises intact.
Minimising Waste & Maximising Recycling
Sustainability isn’t just about energy—it’s about material efficiency too. We recycle 100% of our wax, remelt excess metal for reuse, and monitor consumables across departments to reduce unnecessary waste. By analysing trends and working closely with our teams and suppliers, we’re constantly reducing our environmental footprint while keeping material costs in check.
Customer-Focused Logistics
Our onsite stock holding facilities allow us to manufacture in bulk and ship on demand—reducing transport frequency, supporting customer schedules, and driving down logistical costs.
KPI Monitoring & Continuous Improvement
Monthly KPI reviews at the management level keep every department aligned and accountable. We track, measure, and celebrate improvements—using data to fuel decisions and drive long-term performance gains.
At Lestercast, every process is an opportunity, every challenge is a chance to improve, and every team member is part of our success story. Production efficiency is more than just hitting targets—it’s how we build trust with customers, remain competitive, and secure our place as a leading UK investment casting foundry.