EnerSys Tour Offers Immersive Lean Manufacturing Insights
MLC members explore lean ecosystems, advanced battery production, and agile fulfillment strategies at EnerSys' Richmond facility.
EnerSys’ Richmond, Kentucky, facility opened its doors to Manufacturing Leadership Council members, offering a first-hand look at how a century-old operation has evolved into a benchmark for modern lean manufacturing, assembly and distribution. The visit was more than a tour—it was an immersive experience into lean principles that are not just deployed but embedded holistically across processes, people, and locations. The EnerSys Operating System and the integration of traditional and advanced battery production demonstrated the power of scalable lean ecosystems that operate seamlessly in both legacy and digitally transformed environments.
The Richmond site produces battery chargers and batteries, some weighing as much as two tons. The batteries produced in Richmond include traditional lead-acid motive power batteries for industrial equipment, maintenance-free thin plate pure lead (TPPL) batteries, and lithium-ion batteries. Tour participants made their way through the company’s Mega Distribution Center and the battery manufacturing facility.
One highlight of the tour was EnerSys’ innovative 24-hour “book-and-ship” program, demonstrating how lean principles have enabled fast and flexible responses to customer needs. Visitors also observed how EnerSys identifies and eliminates waste to improve efficiency and enhance sustainability. This included a deep dive into how employee-led initiatives, coupled with digital tools, have driven continuous improvements in product quality, workplace safety and other areas.
These employee-led initiatives play a critical role in driving continuous improvements in quality, safety, and operational performance. Tour attendees were also invited to engage directly with these processes by completing Accountability Tag cards—an exercise EnerSys employees regularly use to spot and address operational deficiencies. The cards prompted participants to document potential problems, propose quick fixes, and complete a 5 Whys analysis to uncover root causes.
The tour concluded with two breakout sessions and a panel discussion and Q&A session where EnerSys leaders answered participants’ questions. The company’s leaders focused on the challenges of scaling the EnerSys Operating System, the role of technology in their processes, and what’s next for the company.
Participants left the event with actionable insights to apply within their own organizations. Many were inspired by EnerSys’ ability to seamlessly blend traditional manufacturing with modern technology, proving that even legacy operations can achieve agility and innovation.
All photos by Ian Wagreich / National Assoc. of Manufacturers, Copyright 2024
