Even in facilities with mature continuous improvement (CI) practices, hidden inefficiencies can go undetected, costing time and money. Magna International, a leading global automotive parts manufacturer, faced a puzzling productivity gap despite optimized machine performance and seemingly minimal downtime.

The Challenge:

Magna’s CI team suspected inefficiencies during shift transitions and breaks but lacked the granular data to verify it.

The Solution:

After implementing Shoplogix, detailed loss analytics revealed an unexpected cause: employees waiting to use microwaves during breaks, leading to production delays.

Key Results for Magna:

• 70% reduction in break and shift transition delays
• $520,000 in annual savings
• Enhanced visibility into previously undetectable production losses
• Empowered CI teams to take targeted, data-driven action

Even the most minor inefficiencies can have a major financial impact. With Shoplogix’s real-time analytics, manufacturers can identify hidden production barriers, drive engagement, and turn overlooked issues into significant savings.