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The challenge

As a result of the global financial crisis in 2009, productivity and plant reliability were suboptimal, while energy, labour and operating costs were high. Alongside this, Incitec Pivot Ltd (IPL) had just acquired Dyno Nobel, a manufacturer of explosives and initiating systems (IS) for use primarily in the mining and quarrying sector.

The Dyno Nobel business acquisition included Ensign-Bickford Company (EBCo), which had a relatively mature Lean manufacturing culture within their North American IS manufacturing function. The IPL Executive Team wanted to leverage this IS continuous improvement culture globally into the entire IPL group.



IPL produce a wide range of explosives, fertilizers, and industrial chemicals. As well as owning and operating 20 plants in the US, Canada, Australia, Mexico Indonesia, and Turkey, the company has joint venture operations in South Africa, Malaysia, China, and Australia.

Over the course of five years the TRACC-powered Bex program enabled the IPL team to achieve step change results, including:

AU$570 million+ in EBIT gross benefits

AU$300 million reduction in working capital

20% improvement in OEE at Initiating Systems plants

35% reduction in recordable safety-related injuries

85% reduction in injury severity

Record output at IPL’s largest chemical plants globally

From our clients

“I am convinced that the principles of TRACC can be applied successfully to any organization. The results at IPL speak for themselves – you can’t argue about half a billion dollars in productivity savings.”

James Fazzino, CEO, IPL

From our clients

“The real value of TRACC and what differentiates it from other common business improvement offerings is the assessing and planning capability. Its structure is also particularly helpful.”

David Walker, BEx Manager

From our clients

“I’ve been involved with numerous business improvement initiatives during my career, but most of them were tool-based and sustaining them was difficult. TRACC provides detailed guidance and a recommended road map of how to achieve, and subsequently sustain, world-class performance.”

Rina Patel, Site Manager

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