How Magna Saves 2,500 Hours Annually with Mobile2b?

Magna, a leading manufacturer in the German automotive industry, has significantly optimised  its operational efficiency, audit and quality control through its partnership with Mobile2b. By digitizing the entire audit process, Magna saves 2,500 hours per year. 

Tobias Wessely, Project Manager of Smart Factory / Industry 4.0 at Magna Powertrain, underscores this achievement, stating:

 “Our project success with Mobile2b is due to their innovative system and practical mentality.”

Let’s explore some of the key methodologies and tools used in achieving these remarkable results.

Key Methodologies and Tools Used

5S Methodology (Sort, Set in Order, Shine, Standardize, Sustain)  

5S is a workplace organization method that optimise efficiency and safety by systematically organizing and cleaning the work environment.

• Comprehensive 5S Workflows: Mobile2b implemented thorough checklists and questions into Magna's 5S workflows, streamlining processes and ensuring a clutter-free, efficient workplace.

Try the 5S Checklist App for free now.

Layered Process Audit Checklist (LPA)

Layered Process Audits (LPA) ensure that critical processes adhere to standards and are executed consistently through multi-tiered management audits.

• Regular Process Audits: With Mobile2b's guidance, Magna conducts frequent, multi-tiered audits that ensure adherence to established standards and identify opportunities for continuous improvement.

• Structured Issue Handling: Any "not OK" responses during checks automatically trigger the creation of new tasks, ensuring immediate action and resolution.

Try the Layered Process Audit Checklist App for free now.

SBI (Standardized Work Instructions)

Standardized Work Instructions (SBI) provide detailed documents outlining the most efficient way to perform tasks, ensuring consistency and reducing variability.

• Consistent Process Documentation: Mobile2b ensured that operational processes are meticulously documented and standardized, promoting consistency and minimizing errors across all levels of the organization.

TPM (Total Productive Maintenance)

Total Productive Maintenance (TPM) is a proactive approach that maximizes equipment efficiency by preventing breakdowns and ensuring optimal performance through regular maintenance.

• Proactive Maintenance Schedules: Through Mobile2b's support, Magna implemented TPM, allowing regular proactive maintenance, minimizing downtime, enhancing equipment efficiency, and extending the lifespan of their machinery.

VDA (Potential Analysis and Process Audit)

VDA standards involve thorough evaluations of processes to identify inefficiencies and areas for improvement, ensuring quality and compliance.

• In-depth Audits: Conducting detailed audits based on VDA standards, helped to identify potential improvements, optimize processes, and ensure compliance with industry norms and best practices.

IATF 16949 (International Automotive Task Force 16949)

IATF 16949 is a global quality management standard for the automotive industry that focuses on continuous improvement, defect prevention, and waste reduction in the supply chain.

• Strict Quality Management: Adhering to IATF 16949 standards, Magna ensured it's quality management systems meet the rigorous demands of the automotive sector, fostering reliability and excellence.
  
  

Workflow and Issue Handling

Dynamic Job Creation and Delegation

Systems automatically generate and delegate new tasks in response to "not OK" checks, ensuring immediate action and continuous improvement through rechecks and follow-up actions.

• Automated Task Creation: Mobile2b's systems automatically generate new jobs when a "not OK" response is recorded, assigning these tasks to the relevant personnel for immediate action.

• Efficient Task Management: Tasks can be marked as "job done" or further delegated. Upon completion, a recheck (CCAR job) is assigned to a supervisor, who can approve the task or create follow-up actions, ensuring a continuous improvement cycle.

API Utilization

Data-Driven Analysis and Improvement

API allows Magna to monitor deviations and analyze responses, enabling targeted process enhancements based on data-driven insights.

• Monitoring Deviations: Utilizing Mobile2b's API, Magna monitors the number of deviations and analyzes responses.

• Targeted Process Enhancements: By tracking frequently occurring "not OK" responses, Magna can pinpoint specific areas requiring improvement. This data-driven approach enables the implementation of targeted process enhancements, resulting in significantly increased operational efficiency and quality.

Outcomes

Implementing these methodologies and tools has led to substantial improvements in Magna's operational efficiency and quality control. A proactive and structured approach ensures consistent adherence to industry standards and continuous process improvement and optimization.

Benefits

• Increased Operational Efficiency: Streamlined workflows and proactive maintenance schedules have dramatically reduced downtime and boosted overall productivity.

• Enhanced Quality Control: Regular audits and standardized work instructions have improved adherence to quality standards, ensuring consistently high-quality outputs.

• Data-Driven Decision Making: Utilizing the API for in-depth data analysis has enabled informed, targeted improvements, leading to superior operational outcomes

Magna's commitment to operational excellence and quality control is demonstrated through their structured approach and relentless pursuit of continuous improvement. By leveraging these methodologies and tools, they have established a robust system that ensures high efficiency and top-quality standards.

Additional Insights and Future Prospects

Continuous Training and Development

Employee training programs ensure staff are well-versed in the latest methodologies and tools, fostering a culture of quality and efficiency.

• Employee Training Programs: Mobile2b helped Magna develop comprehensive training programs for their staff, ensuring they are well-versed in the latest methodologies and tools. This continuous education fosters a culture of quality and efficiency.

Technology Integration

Integrating the latest technology solutions into operations, from automation to real-time data analytics, has revolutionized processes, making them more efficient and reliable.

• Advanced Technology Solutions: Integrating cutting-edge technology solutions into their operations. From automation to real-time data analytics, these technologies have optimized the processes, making them more efficient and reliable.

Sustainability Efforts

• Eco-Friendly Practices: In collaboration with Mobile2b, Magna has also focused on sustainability. Implementing eco-friendly practices in their operations not only enhances efficiency but also aligns with their commitment to corporate social responsibility.

Future Prospects

Plans to expand these methodologies across other divisions and new projects will replicate the success story and further solidify Magna's position as an industry leader.

• Expansion Plans: With the success achieved through teamwork, Magna is now planning to expand these methodologies across other divisions and new projects. This expansion will help replicate the success story and further solidify its position as an industry leader.

Customer Satisfaction

• Enhanced Customer Experience: The improvements in operational efficiency and quality control have directly contributed to higher customer satisfaction. Magna's clients benefit from more reliable products and services, fostering stronger relationships and brand loyalty.

Competitive Edge

Consistently implementing best practices and staying ahead of industry standards maintains a competitive edge in the market.

• Market Leadership: By consistently implementing best practices and staying ahead of industry standards, Magna maintains a competitive edge in the market. Mobile2b's strategic insights and tools have played an important part in achieving this position.

Conclusion

Magna's success story is a testament to the power of Mobile2b's advanced features, tools, and determination to improve operational efficiency, audit, and quality control. This proactive, structured approach not only meets but often exceeds industry standards, setting Magna apart as a leader in the field. Through continuous improvement and data-driven decisions, Magna continues to achieve operational excellence and superior quality, driving long-term success.

Experience the transformative power of Mobile2b for yourself. Optimize your operational efficiency, and quality control, and save valuable time by digitizing your audit processes. Partner with Mobile2b and achieve remarkable results. Book a free consultation to learn more about how Mobile2b can transform your operations, audit, and compliance processes now.