Imperial Die Casting- Embracing a Lean Culture

As all four RCM Industries die casting divisions make productive strides towards lean manufacturing implementation, the successes associated with Imperial Die Casting’s lean journey are worth highlighting.

In summary, True Lean is a comprehensive management system with a focus on systematic problem solving. All layers of the organization are responsible for identifying value in their process and eliminating waste. With a foundation of standardization and incremental continuous improvement, benefits can be achieved for customers, employees, and the organization as a whole. Through training at the University of Kentucky (UK), each RCM division is modeling their company vision after the Toyota Production System, then developing strategies to transform and sustain.

For a full summary on the corporate lean manufacturing initiatives by RCM Industries, please view RCM Industries is Going Lean.

Below are a few examples that illustrate Imperial’s successful lean journey. Please click on the pictures to enlarge.

Specific areas of the plant were targeted for improvement in product flow. For example, after 5S, specific machining equipment was identified for relocation to create additional product rack space in an effort to improve product flow and inventory process.
Relocation 1Relocation 3Relocation 4





Die Casting setup areas were targeted for improvement. New additions after 5s include visual reference guides for different sized components, improved storage racks and shelving for component storage, and new setup areas consisting of repurposed materials.

Setup area beforeSetup area afterPicture2






Standards have been implemented for die casting workspace cleaning.

Standard Die Cast Cleaning







New and improved walkways were created to improve plant safety while improving the layout of the plant. During these efforts, the decision was made to move the quality assurance inspection area away from the shipping coordinators doorway to make more room for product ready to ship. Team members contributed greatly to these efforts, and took great pride in the work being accomplished.

Walkway 3QA1QA2






Improved lighting has been added to the new quality assurance inspection area. In addition, an inspection monitoring system has been implemented to replace the current paperwork processes.

QA lab 1QA lab 2






The production packaging storage area before and after 5s; identified space for customer product and packaging.

packaging 1packaging 2






Stock is kept of the tools team members need to perform daily work, including paint, pens, markers, safety glasses, and other items. Team members scan their badge to get the tools they will need.

Tool Stock






For additional information pertaining to RCM Industries’ Lean journey, please do not hesitate to contact us. For additional information on the training programs provided by the University of Kentucky, please view: