If you want a concise case study in lean automotive engineering, look at how Munro optimized the Club Car design. In this project, Munro & Associates used teardown analysis, customer feedback, and manufacturing-focused design to reinvent both the golf cart platform and its business model — lessons that apply directly to EV design and other low-volume vehicle programs.
Why Golf Carts Matter to EV Engineers
Golf cars operate under strict cost and durability constraints; they’re perfect laboratories for lean design. Munro’s Club Car optimization started by benchmarking the top global competitors bolt by bolt to see where the industry was headed, then interviewed course pros, maintenance staff, and groundskeepers to clarify real needs. That approach surfaced two core insights: reduce turf damage and keep riders dry without adding cost or complexity.
Designing for the Customer and the Course
A small shift in track width can reduce rutting on wet grass; redesigning the water path can keep both golfers and the course drier. The team integrated a “monsoon cover” — essentially a built-in gutter — to capture rainwater and channel it away from occupants and wheels. Simple, customer-driven features like these create outsized value when they’re baked into the architecture rather than bolted on later.
From Parts Proliferation to Part Integration
Munro’s Design Profit methodology asks two blunt questions of every interface: does the part need to move relative to its neighbor; does it require a different material? If the answer is no, integrate. This teardown-driven discipline produces a theoretical minimum part count, guiding the team toward simpler structures, fewer fasteners, and shorter cycle times. The approach results in a leaner bill of materials, reduced quality risks, and quicker ramp-up — a hallmark of golf cart engineering optimization that also applies to broader EV manufacturing lessons.
Module the Pain Points
The original front suspension was built up piece by piece, with camber and toe set on the line — a slow, variation-prone process. Munro converted it to a pre-built chassis module: assemble offline, set alignment once, then dock it to the frame in minutes. The same thinking extended to a service-friendly “bucket” module containing the battery and electronics. Operators hoist it into place, make a handful of connections, and move on; maintenance later becomes faster because critical components are easy to access.
Re-thinking the Frame: Extrusions + Composites
Legacy frames used complex welded aluminum cages — costly, heavy on fixtures, and slow to build. Munro replaced this with two extruded aluminum side rails capped by a two-piece composite floor pan. The halves drop over the rails, are vibration-welded, and then secured with automated self-driving screws. This hybrid structure slashes part count and weld time; consistency improves while openings for modules and wiring remain accessible.
Lean Manufacturing Starts at Design
Because the architecture was created with the line in mind, plant layout became a value lever, not an afterthought. Munro helped specify modern equipment, design ergonomic workstations, and place material for easy reach so operators could build more in less time. Critically, the team used a low-rate initial production area to build the first 500 units with suppliers running their own tools on site; issues surfaced early instead of on the main line.
Accessory Strategy: Engineer the Aftermarket
Golf carts live two lives: on the course and in communities. In their optimization efforts, Munro designed a common attachment architecture for the Club Car so accessories — sand bottles, baskets, coolers — mount the same way everywhere. They even turned a tool-access slot on the sand bottle into a “fuel-gauge” window so users can see fill level without extra parts — a small, “bewitching” delight that adds perceived quality at near-zero cost. Likewise, preplanned harness connectors for lights and add-ons cost pennies up front but let the OEM capture accessory revenue later while simplifying installation.
Outcomes: Cost Down, Throughput Up, Market Share Won
The combined effect of modularization, part integration, and a smarter frame was dramatic. Assembly times fell; ergonomics improved; quality stabilized because fewer adjustable operations happened on the line. With lower conversion costs, the manufacturer could price more aggressively while protecting margin. Performance and styling advances made the vehicle more desirable; market share increased as a result.
Transferable Lessons for EV Programs
- Start with evidence. Benchmark competitors and listen deeply to users; it focuses the spec and prevents gold-plating in any lean design case study.
- Force part-count decisions early. A theoretical minimum parts model becomes a north star for integration.
- Module what varies. Anything alignment- or calibration-intensive should move off-line into pretested modules.
- Hybridize structures. Pair extrusions with thermoplastics where it reduces weldments and tooling while preserving stiffness.
- Design the line with the product. Layout, ergonomics, and in-station material presentation are engineering problems; treat them that way.
- Monetize the accessory ecosystem. Common mounts and pre-wired connectors delight customers and convert aftermarket chaos into predictable revenue.
What This Means for Investors
Lean architecture expands options. When you drop touch labor and station time, you limit capital intensity and derisk ramp; cash conversion improves. Pricing becomes flexible, and the platform can scale into adjacent markets — fleet, resort, or neighborhood mobility — without retooling the factory. These are the same levers winning EV segments today.
Limitations and Trade-offs
There are caveats. Vibration welding demands process control and fixture precision; composite floor pans must manage heat, fastener pull-out, and long-term creep. Accessory pre-wires add small unit costs to every vehicle, whether or not a buyer uses them.
Yet the lessons from Munro’s optimization of the Club Car design show that when the use case is well understood, system-level savings typically outweigh part-level additions — a core principle of lean design.
The Bottom Line
For engineers and product leaders, Munro’s Club Car redesign delivers a clear guide. It demonstrates how to integrate aggressively, modularize alignment-heavy subsystems, and design manufacturing into the CAD from day one.
For operations teams, it highlights how smart pilot runs and supplier-on-site trials accelerate launch success. And for investors, the case proves lean design is more than a philosophy. It operates as a direct earnings driver — turning efficiency into measurable profit.
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