Zero Defects And Beyond Mistake-proofing wins Collins & Aikman's Americus Operation DaimlerChrysler gold. ByGlenn Hasek Collins & Aikman, Americus Operation, Americus, Ga. At a Glance
Web-Exclusive Best PracticesByGlenn Hasek Benchmarking contact: Bob Carney, vice president of operations,
[email protected], 229/928-8208
Abundant Good Deeds Employees from Collins & Aikman's Americus Operation are very active in the local community. An annual Good Friday Golf Tournament raises thousands of dollars. In 2001, $10,000 was raised for the American Cancer Society. Employees also participate in the Relay for Life cancer walk. During the Christmas season, employees donate to underprivileged children and each area of workers in the plant adopts a family and provides gifts to them. Three years ago a Bikes for Tikes program was launched. Employees purchase bicycles, which are then donated to needy families with children. Plant employees also participate in fund-raising activities for the Muscular Dystrophy Association, the National Heart Association and the American Red Cross. A quarterly blood drive is held at the plant. Employees also participate on the board of directors of the Girl Scouts of America. Americus Operation members support local schools by attending job fairs and conducting tours of the facility for area students. "We have a long list of community initiatives that we are proud of," says Bob Carney, vice president of operations.
Easing Back To Work When employees at Collins & Aikman's Americus Operation return to the plant after an illness or injury, they are not required to return to their previous jobs until they are ready. A "Work Hardening" program at the plant helps ease them back to full strength by offering less strenuous but equally important duties. The transitional work provides a value-added function, freeing up another employee for training/personnel development, or projects that improve the efficiency of the operation. The plant provides an "Injury and Illness Form" that enables an employee's physician to define the person's work restrictions. The employee returns the completed paperwork to the nurse practitioner after every doctor visit. The nurse practitioner helps determine value-added work for the employee. "We try to keep employees on the job," says Sam Holden, EHS coordinator. "The longer an employee stays out of a job, the longer it takes for them regain their skills and strength."
- Plant size: 534,000 square feet
- Start-up date: 1976
- Special Achievements
- DaimlerChrysler Gold Award Winner in 2000 and 2001
- No. 1 Exterior Part Supplier for DaimlerChrysler in 2000 and 2001