4 minute read
We speak iron
WE SPEAKIRON
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Forward thinking keeps 123-year-old foundry burning
By Paula Schuck Despite World Wars, the Great Depression and more recently the world-wide pandemic, Lethbridge Iron Works has kept burning. Continuously operating since 1898, Lethbridge Iron Works has a lot of Canadian pride. Family-run Lethbridge Iron Works began operating in Lethbridge, Alberta well before Alberta was officially recognized as a province. Founded by George Davies, today, the president of the company, Dylan Davies, is a fourth-generation family member. The company, employing 175 people, has grown and adapted over the years to be able to continue doing what they do best. They are thriving and currently hiring. Lethbridge Iron Works produces Grey Iron, Ductile Iron, Austempered Ductile Iron, Carbidic Austempered Ductile Iron and Hi-Chrome Iron castings. They are a single source iron casting provider. Investment in a continuous capital improvement program has ensured they are at the leading edge of foundry technology. They use robotic finishing and automated production systems, and are known for having a short lead time.
“We ship iron castings throughout North America, from the Atlantic to the Pacific, and everything in between,” says Mark Mundell, Director of Sales for Lethbridge Iron Works Co. Ltd. The business has expanded multiple times in the last few years. Still located in Lethbridge after 120 years, they have a modern production foundry of over 110,000 square feet. Use of up-to-date technology sets them apart, including two automatic storage and retrieval systems, Six Foxall™ Robotic Grinding Systems and the use of ignition software for collecting, controlling, and visualizing data throughout the process.
Transforming designs into cast reality
“We are more of a service industry. I don’t have a widget that I sell. Instead, we work with companies and engineers to transform their designs into a cast reality,” Mundell explains. Business is about a 50:50 split between Canada and the U.S., serving basically every industry sector imaginable. “The interesting part is that it is built in Canada, but at the end of the day we can ship to anywhere in the world,” says Mundell. “We are growing and have been expanding significantly in the last three years. Some of that has been driven by things like increased tariffs and North American initiatives to buy local, but also by our focus on providing our customers with a unique experience. We need to be competitive, but most important to our relationships is the need and commitment to being honest, transparent, adaptable and fulfilling our promises.”
In the last decade, the business has made significant investments in automation and infrastructure that have kept them at the forefront of their industry. “We took a hard look at our processes about 10 years ago with an eye to automate as much as possible. That was a strategic decision that we made at the right time.” Lethbridge Iron Works began looking at robotics during the oil and gas boom in Alberta. It was hard to find people then and while the economy has changed many times, the piece that remains true today is that it is still as challenging to find employees. “I’d hire you right now if you put in an application,” Mundell says. He notes that every company is limited at some point as to how much can be automated. “With the people challenge remaining an issue, a lot of companies are forced to evaluate and re-evaluate their business model. If you can’t grow your business easily then you have to start thinking about what you are doing and who you are doing it for. When expansion isn’t doable because of your most precious resource - people - then you must really look hard at partnerships and doing things differently. It is a new world. “We all face challenges as to how we grow with these new limitations," says Mundell, who went to school in Lethbridge and started out at Lethbridge Iron Works cutting grass in the summer months.
“As a company that has been operating in Canada since 1898, our pride and formula for success has been relationships. Getting through this pandemic and continuing as the Canadian foundry of choice will only be achieved if we don’t lose sight of the value of relationships and of our people. “For 123 years, we have made Canada our home, employing Canadian people and contributing to Canada’s economic success. We have no plans to stop this anytime soon. “When you think about it, it’s impressive that the 50 per cent or more of current sales are into the U.S. considering buy American initiatives, and that we have continued to grow throughout the decades of low-cost offshore sourcing initiatives in North America. Our castings are identified by ‘Made in Canada’ or a small maple leaf and can be found in use throughout the world.”
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