Implementing Six Sigma at E-Z-GO Engineering Lab Services
1. The SIX SIGMA way of thinking at many organizations including E-Z-GO-Textron,
simply means a measure of quality that strives for near perfection. This tool has helped
organizations of all types and sizes improve the quality of processes and products while
simultaneously increasing customer satisfaction and saving a tremendous amount of
money
Six Sigma; this disciplined, data-driven approach and methodology for eliminating
defects (driving towards six standard deviations between the mean and the nearest
specification limit) in any process -- from manufacturing to transactional and from
product to service was used to help transform the 50-year-old R&D/Engineering Lab
Services workspace into a Premier World Class facility.
Engineering Lab Services (also known as “R&D”), department 788 is a service
organization to E-Z-GO Engineering and Manufacturing when a quality or test related
incident arises. To buy into a culture quality processes and quality services, a tremendous
change was needed. The business leaders in Engineering had the foresight to see great
issues facing the business. They made sure that this department was striving towards The
E-Z-GO Mission: “We the employees of E-Z-GO, A Textron Company, are committed
to being the world's premier provider of people and burden carrier vehicles. We will
succeed through talented people, world-class processes, and setting the benchmark for
product quality and customer satisfaction.” As a service organization “World’s
Premier…World-Class Process…Product Quality and Customer Satisfaction” are all in
line with the Six Sigma way of doing business.
Leacroft “Lee” Lawrence came to E-Z-GO in April of 2005. He worked as a Mechanical
Engineer in an aerospace company Sikorsky Aircraft Company, UTC. United
Technologies Corporation (UTC) is a diversified company whose products include
Carrier heating and air conditioning, Hamilton Sundstrand aerospace systems and
industrial products, Otis elevators and escalators, Pratt & Whitney aircraft engines,
Sikorsky helicopters, UTC Fire & Security systems and UTC Power fuel cells. UTC
provides a broad range of high-technology products and support services to customers in
the aerospace and building industries worldwide.
In January of 2004 he received his Six Sigma Black Belt Certification from Villanova
University as a part of his Lean/Six Sigma Training from UTC. Upon arrival at E-Z-GO
Textron he saw a world of opportunity to implement his training and pass on knowledge
to the department in which he worked.
E-Z-GO Engineering Lab Services, Department 788 has embarked on a process
improvement and department renovation/lab services overhaul in September 2006. John
Garrison signed his signature on 8/22/2006 onto Capital Appropriations Request, CAR#
6002, for Engineering Labs Services and Reorganization. Edward N. Heinz, Lee’s
supervisor placed him on this project renovation as a Project Champion along with Todd
O. White and Samuel D. Smith. He knew that Lee would bring quality ideas to the
project and continue with process improvement in the months to come.
2. Selecting the right project can have a tremendous effect on your business. If done
properly, processes will function more efficiently in 3 to 6 months; employees will feel
satisfied and appreciated for making business improvements and ultimately even
shareholders will see the benefit. The 5S’s that we benchmarked for the department.
• SORT out unnecessary items, removing them to an area where they are needed,
or discarded
• SET in ORDER necessary items, placing them at hand, with defined locations
• SHINE equipment by thoroughly cleaning and examining it regularly for early
detection of wear, leaks, and other precursors of major breakdowns
• Standardize organization and gain visual control throughout your operation,
simplifying training and rotation of personnel ·
• Sustain the gains through communication and discipline, achieving ongoing
improvements as employees embrace the changes and make them part of their
daily activities
The Renovation Project Ran as a 3-Phases Venture:
Phase 1: Construction (Deconstruction) and Painting
Phase 2: Electrical Work and Lighting
Phase 3: Flooring, Machinery & Equipment
During the renovation process Vlajko Novakovic renovated the Test Engineering Offices
and added a new Break Room for Production Engineering, Dept 697. Photo’s are below.
Test Engineering Offices – Before Photos
Test Engineering Offices – After Renovation Photos
3. ENGINERING LAB SERVICES MODEL SHOP
Model Shop Hardware Bins - Before
Model Shop Hardware Bins – After
YELLOW= MISCALENOUS Hardware, RED=Metric Hardware, BLUE=Standard Hardware,
LAB LIGHTING – Before LAB LIGHTING – After
5. BEFORE SIX SIGMA
AFTER SIX SIGMA
This project is in the final stages in preparation for a new era in streamline process. The
continuous improvement story continues.
6. BEFORE SIX SIGMA
AFTER SIX SIGMA
This project is in the final stages in preparation for a new era in streamline process. The
continuous improvement story continues.
