IndustryWeek Names E-Z-GO as One of 2009’s Best Plants of the Year

AUGUSTA, Ga.--A combination of world-class practices, advanced technologies and improvement strategies led to E-Z-GO’s World Headquarters being named one of IndustryWeek magazine’s 2009 Best Plants of the Year. The company’s World Headquarters in Augusta, Ga. manufactures all E-Z-GO vehicles sold worldwide.

According to IndustryWeek, despite possibly the roughest economic conditions in many decades, the winning manufacturing facilities still pursued process and people improvements, and achieved enviable performance metrics in numerous operational areas. E-Z-GO, a Textron Inc. company, is one of only 10 North American manufacturing facilities to receive the honor.

“In the face of challenging economic conditions, E-Z-GO has maintained a Lean corporate culture and has relentlessly pursued improvement and progress toward key company goals,” said Kevin P. Holleran, president of E-Z-GO. “I couldn’t be prouder of our employees, whose energy, enthusiasm and diligence in driving E-Z-GO on its journey of continuous improvement are the reasons why the company has achieved this important distinction today.”

E-Z-GO was evaluated by a panel of IndustryWeek editors, who also solicited independent evaluations from manufacturing experts and other knowledgeable persons. Specifically, the judges’ panel looked for evidence of:

Management practices geared to motivating achievement of breakthroughs in operating performance and customer satisfaction, as well as cultivating continuous improvement. E-Z-GO uses an annual planning process that identifies key drivers of customer satisfaction and operating performance each year and sets company goals based on those drivers. Each department and employee’s annual performance goals are established based on those company goals, ensuring that the entire organization is focused on a common set of goals.
Strong quality systems and results, including evidence of low defect rates and good process-control capability. E-Z-GO has implemented numerous quality-control processes using Six Sigma methodologies, leading to a plant-wide first-time quality rate of greater than 98 percent.
Extensive employee involvement and empowerment programs, especially efforts to create and provide training for high-performance work teams. E-Z-GO has trained employees at every level of the company in Six Sigma methodology and Lean manufacturing philosophy, including 230 hourly associates who attended “Lean Technician Training” in early 2009. The company also enjoys the highest employee-engagement rating of any business unit within Textron.
A strong customer focus, including formal customer-satisfaction programs, customer involvement in product design, employee contact with customers, and efforts to reduce customer lead times. E-Z-GO uses numerous initiatives, including quarterly customer-satisfaction surveys, field visits to customer facilities, and after-sale contact with customers at fixed intervals to determine long-term customer satisfaction with E-Z-GO. E-Z-GO also formally gathers “the voice of the customer” as a fundamental driver in product design.
Effective supplier-partnership programs, including efforts to solicit supplier evaluations of plant practices. E-Z-GO has numerous supplier-partnership initiatives, including an annual supplier conference and regular meetings between E-Z-GO leadership and the management of key suppliers, in order to share best practices and find solutions to common issues. These initiatives have helped E-Z-GO identify and solidify relationships with key suppliers, allowing the company to reduce its supply base by more than 60 percent while simultaneously improving the quality and delivery times of supplied parts.
Appropriate use of technology, as required by changing business needs. E-Z-GO uses advanced manufacturing technology, including a lineside manufacturing execution system and “smart tools,” to ensure product quality.
Flexible and/or agile production systems capable of responding quickly to customer needs and shifts in the marketplace. The flexibility may be the result of intelligent automation and information technology, just-in-time/continuous-flow production systems, use of quick-changeover methods, a multiskilled workforce, small-lot production, focused-factory plant design, or other lean initiatives. E-Z-GO has numerous systems and Lean initiatives in place to help it move at the “speed of the customer,” including in-house robotic welding and fabrication of key components such as vehicle frames, on-site vendor-managed inventory, material-handling processes that include common-parts warehouses and a Kanban system, an extensively cross-trained workforce, and the rigorous manufacturing execution system, among others. Lot sizes have been reduced by 67.5 percent, on average, over the last three years, and average changeover times have improved by 15 percent.
Improvements in manufacturing operations, including shortening of manufacturing cycle times, improvements in productivity, and reduction of inventories. E-Z-GO’s usage of Six Sigma and Lean methodology have led to an 18.5 percent decrease in manufacturing cycle time over the last three years. E-Z-GO also improved inventory turns by 30 percent from 2005 to 2008, and improved productivity by 31 percent.
Proactive environmental and safety practices. E-Z-GO’s behavior-based safety program has empowered employees to look after their own safety and the safety of others, resulting in consistent world-class safety performance. The company also employs a three-pronged approach to environmental stewardship – including the design of environmentally friendly products, the use of eco-friendly manufacturing processes, and the engagement of its employees in constantly seeking new ways to reduce the company’s environmental footprint. These practices helped E-Z-GO decrease energy consumption by 10 percent year-over-year from 2005 to 2008, and reduce plant water consumption by 86 percent over a six-year period.
Meaningful community involvement and support programs. E-Z-GO sponsors and supports numerous community organizations and events in the Augusta area, and was the driving force behind the Augusta Metro Chamber of Commerce’s Manufacturer’s Exchange, which brings together prominent local manufacturers for networking, discussion of common issues. E-Z-GO’s annual Boys and Girls Clubs Golf Tournament, now in its 15th year, has raised more than $725,000 for the Boys and Girls Clubs of Augusta. In addition, E-Z-GO’s employee-led community-service organization, Team E-Z-GO, raises money for local charities and organizations such as the American Heart Association and American Cancer Society.

The IndustryWeek recognition capped a banner year in which E-Z-GO also received the Shingo Prize for Operational Excellence – dubbed “the Nobel Prize of Manufacturing.” E-Z-GO is the first and only company to receive the prize at the enterprise level -- meaning that E-Z-GO was recognized for world-class status at all of its geographic locations and across all business functions, including manufacturing, engineering, sales, finance, marketing, communications, supply chain management, information technology, and human resources. E-Z-GO was also a finalist for the IndustryWeek honor in 2008.

“Our philosophy of continuous improvement and employment of Lean methodology and Six Sigma practices have led to dramatic performances in eliminating wasteful practices and driving enhanced productivity and customer satisfaction,” Holleran said. “But, as I’ve said before, this is only the beginning. E-Z-GO is committed to continued innovation and improvement so that we can continue to exceed our customers’ expectations, provide a safe and respectful workplace, support our community, protect our environment, and drive value for Textron shareholders.”

For more information about E-Z-GO vehicles, please visit www.ezgo.com or call 1-800-241-5855.

About E-Z-GO

E-Z-GO, a Textron Inc. company, is a leading manufacturer of golf cars and utility vehicles. E-Z-GO is the preferred golf car fleet provider for many of the world’s most revered golf courses, clubs and resorts. E-Z-GO is also the golf car of choice of nine of the nation’s 10 largest course-management companies. E-Z-GO boasts the largest sales and service network in the industry, with more factory branch locations and independent distributors than any other manufacturer.

More than a maker of golf cars, E-Z-GO is also a leading provider of turf and utility vehicles for a variety of applications and industries. Products under the E-Z-GO flagship include Shuttle personnel carriers, MPT turf maintenance vehicles, and ST personal utility vehicles. E-Z-GO also produces the Cushman line of heavy-duty material and personnel carriers.

Founded in 1954 in Augusta, Ga., E-Z-GO became part of Textron Inc. in 1960.

About Textron Inc.

Textron Inc. is a multi-industry company that leverages its global network of aircraft, defense, industrial and finance businesses to provide customers with innovative solutions and services. Textron in known around the world for its powerful brands such as Bell Helicopter, Cessna Aircraft Company, Jacobsen, Kautex, Lycoming, E-Z-GO, Greenlee, and Textron Systems. More information is available at www.textron.com.

Special note to Editors: The correct spelling of ‘E-Z-GO’ is with all capital letters and two hyphens.