magna seating doomcb.rs/wp-content/uploads/2017/10/04.-marko-terzić-magna-seati… · global...

MAGNA Seating doo1st KAIZEN CONGRESS, BELGRADE

Marko Terzić,

Continuous Improvement Manager

Global Presence

~161,000 Employees

29 Countries

58 OEM Customers

327 Manufacturing

100 Eng / Product Dev / Sales

$36.4 Billion

(2016 Sales)

NORTH AMERICA

138 Manufacturing / Assembly

25Engineering / Product

Development / Sales

75,750 Employees

SOUTH AMERICA



Development / Sales

3,500 Employees

ASIA



Development / Sales

22,775 Employees

EUROPE



Development / Sales

59,250 Employees

28.09.2017 Magna Seating Marko Terzić 2

Product Systems

SEATING

Capabilities

• complete seating systems

• seat structures, mechanism &

hardware solutions

• specialty mechanism solutions

• foam & trim products

• design & development capabilities

Global Footprint

• 23,825 employees

• 52 mfg/assy facilities*

• 9 product development/

engineering/ sales centers

*including In Progress Facilities

EXTERIORS

Capabilities

• fascia & trim

• liftgate & exterior modules

• front end modules

• active aerodynamics

• lightweight composites

Global Footprint





*including Minority JVs

VISION SYSTEMS

Capabilities

• interior mirrors

• exterior mirrors

• actuators

• door handles

• headlamps

• tail lamps

• small lighting

Global Footprint

• 9,650 employees

• 27 mfg/assy facilities



ROOF SYSTEMS

Capabilities

• soft tops

• retractable hard tops

• textile folding roofs

• modular roofs

Global Footprint

• 2,050 employees




CLOSURES

Capabilities• latching systems• door modules• window systems• power closure systems• handle assemblies• electronics• engineered glass• hinges• wire forming• sealing & trim• running boards• roof racks• composite products

Global Footprint




engineering/ sales centers*

*including Minority JVs


Product Systems

Capabilities

• body systems

• chassis systems

• technology, engineering

& tooling systems

Global Footprint





* including Minority JVs & In Progress Facilities

BODY & CHASSIS

Capabilities

• automated driving systems

• secure connectivity

• electrification

Global Footprint

• 1,925 employees




ELECTRONICS

Capabilities

• engineering services – from

systems and modules to complete

vehicle development

• contract manufacturing – world

class flexible solutions from niche

to volume production

• fuel systems – energy storage

systems made of steel, plastic and

aluminum

Global Footprint





VEHICLE ENG & CONTRACT MFG

FUEL SYSTEMS

Capabilities

• GETRAG transmissions

• driveline systems

• fluid pressure & controls

• metal-forming solutions

• advanced engineering

Global Footprint





POWERTRAIN


Global Presence

28.09.2017 5

$36.4 Billion

2016 SALES

161,000EMPLOYEES

327 global sites

MANUFACTURING MARKET POSITION

#1North America

#3 Globally Magna Seating Marko Terzić

5

1

16

5

20

3

Magna Seating Global Presence

14

7

1,056

South America1,986

Asia

North America12,757

Europe4,621

~23,000 People 17 Countries 50* 15

Manufacturing / Assembly

Engineering / Product Development /

Sales / R&D Centers

Number of EmployeesSeating

JIT Seating 11

Recliners 2

Adjusters 1

Structures 3

Trim 3

Foam + Blending fac. 6

New JIT Facility 1

JIT Seating 3

Structures 3

Trim 2

Foam 2

JIT Seating 11

Structures 1

Trim 4

New JIT Facility 1JIT Seating 5

Recliners 2

Adjusters 2

Structures 7

New JIT Facility 8

* Includes New JIT Facilities

628.09.2017 Magna Seating Marko Terzić

28.09.2017 7

About

• Capabilities– Trim covers production (cutting & sewing)

• Technology– CNC Cutting – fabric, vinyl, sponge

– Standard sewing machines

– Side Airbag machines

– Multi needle machines

• Products– Cutting and sewing of covers for premium passenger

cars and light commercial vehicles

• Projects

• Certified

ISO/TS 16949

ISO 14001 EMS

ISO 18001 OHSAS

Foundation of MAGNA ODŽACI TRIM PLANT : April 2012

Start of production : October 2013

Space (Production) : 10.103m2 (7.143m2)) , from extension in 2017.

No. of employees : 1288 (September 2017)

Magna Seating Odžaci

Magna Seating Marko Terzić

MAGNA Lean conceptMAFACT - Magna Factory Concept


MAFACT - Introduction

28.09.2017 9

• Mafact = Magna Factory Concept

• The purpose of Mafact is to create a common, but unique factory concept for all

Magna Divisions globally, where common operating principles are employed to

achieve our goal to be world class manufacturers.

• This will enable us to satisfy our Customers, to generate healthy profit margins

and to provide employees with a better place to work.

• Mafact makes use of continuous improvement in all our processes to eliminate the

7 types of waste. This is accomplished through the efforts of dedicated teams of

capable individuals that are supported by our Leadership teams.


MAFACT - Introduction

28.09.2017 10

All of our Divisions must reflect the same World Class image and performance to

our Customers, Employees and Shareholders. As a minimum, this means that

– each plant should reflect clean, organized work areas,

– with good visual controls at all times. Production targets should be visual with ongoing

monitoring of outputs to targets.

– People should be well-trained in their responsibilities and in charge of the operation,

– performing work in a standardized way and everything from product development through

purchased components, to the shipping of finished product, should be well controlled.

In essence, each plant should have similar systems in place in order to achieve

this.


8 Pillars


WCM

MAFACT

H&

S / E

nvir

on

me

nta

l

Qu

ali

ty

Ma

nu

fac

turi

ng

Ex

ce

lle

nce

Lo

gis

tic

s

Des

ign

En

gin

ee

rin

g /

AP

QP

Ma

na

ge

me

nt

Co

st

Hu

ma

n R

es

ou

rce

s

What Mafact Covers


Expectations MAFACT Pillars Objectives Tools and Methods

Customer

Satisfaction

Quality

Efficiency

On-Time-Delivery

Simultaneous

Engineering

People

Development

Sensible

Investments

Reliability

Results

Safety

Quality

Timing

Cost

Motivation

Health & Safety /

Environmental

Quality

Manufacturing

Excellence

Logistics

Design

Engineering / APQP

Management

Cost

Human Resources

• Safe Workplace

• Cleanliness and Organization

• Ergonomics

• Environmental Awareness & Compliance

• Preventive Quality Management

• Effective Problem Solving

• Scrap Reduction

• Supplier Management

• Warranty Reduction• Reduction of Waste

• Standardized Work / Consistent Set-Ups

• Line Balancing

• Qualified Employees

• Efficient Processes

• Effective Maintenance

• Continues Improvement

• Good Material Flow

• Material Identification

• Optimal Stock Rotation

• Optimized Inventory Management

• Production Scheduling

• Controlling Changes

• Keeping Records Up-to-Date

• Planning for Product & Process Design

• Meet Business Plan Targets

• Controlling Critical KPI

• Establish Communications & Reporting

• Top Management Involvement

• Openness to Ideas and Suggestions

• Controlling Cost

• Tracking Cost Savings

• Qualified Employees

• Motivated Employees

• Good Communication & Information

• Employee Leadership Balance

• Employee Involvement

• Safety Mindset

• Personal Protective Equipment

• 5S Methods

• Visualization and Identification

• Ergo Risk Assessments and Actions

• Environmental Systems• Incident / PPM Tracking (KPI)

• Zero Defect / Fast Response Board

• A3 Problem Solving Methodology, Quality Tools and Six Sigma

• Scrap Monitoring (KPI)

• Supplier Incident / PPM Tracking (KPI)

• Warranty & Cost Monitoring (KPI)• 7 Types Of Waste

• Standardized Work Recording / Combination Table and Chart

• Line Leveling

• On the Job Training in Production Processes & Problem Solving

• TPM

• OEE

• Ongoing Continues Improvement & Problem Solving

• Material Movement – Quantities and Frequencies

• Labeling and FIFO

• Min/Max Inventory Levels / Supermarkets

• Line Supply

• Pull System / Kanban

• DFSS

• FMEA

• Effective Project Management

• Lessons Learned / Benchmarking

• Effective Change Management

• Record Keeping• Business Planning

• KPI Monitoring & Actions

• Contol & Information Boards

• Daily Operations Meetings

• Process Audits

• MAFACT Approach

• Bill Of Material Reviews

• MCRP

• Cost Of Quality KPI Monitoring

• Purchasing / Engineering / Continues Improvement Cost

Savings KPI

• Recruiting Process

• Training for all Employees

• Employee Performance Appraisals / Employee Opinion Surveys

• Employee Information Systems

• Leadership Methods

• Employee Involvement / Reward and Recognition

Magna Industry 4.0 - Initiatives


• World Class Manufacturing as one of Magna’s “Top 3 Initiatives”

• Magna implemented the Global Initiative “Agenda 2025”– High Level Management involvement

– Grouped by Functionality (JIT, Trim, Metals, …)

– Working Levels with individual Tasks

• Magna Seating in liaison with by Magna Steyr regards “Smart Factory”

Serial Production

Product Design and Development

Process Design and Development

Magna Industry 4.0 - Current Status


Process

Simulation

Simulation

Product and Process Validation

Mat. Flow

Simulation

Packaging

Simulation

CAD

RoboticsVision

Systems

3D

Printing .

Testing

Simulation

PT 3D

Printing.

Design

Verification

Process

Simulation

3D

Printing

Assembly

Simulation

Forecast

Simulation

Equipment

Simulation

Ergonomic

Simulation

MAGNA ODŽACIContinuous Improvement


7 Types of Waste

• Waste is anything in the process that is non value added (ie what the

customer doesn’t pay for).

• Walking, moving parts, unpacking, reworking, waiting, correcting,

scanning.

• In general, lean mfg identifies 7 types of waste (plus 1).

• State some examples of value added, non value added work and waste!


TOP KAIZENS – BROKEN SEAM


Critical X 1

Critical X 2

Critical X 3

Critical X 4

TOP KAIZENS – PRODUCTION BACKLOG


Problem: Production backlog

Critical X 1

Critical X 2

Critical X 3

Critical X 4

TOP KAIZENS – INVENTORY DISCREPANCIES


Problem: Inventory discrepancies

Critical

X 1

magna seating doomcb.rs/wp-content/uploads/2017/10/04.-marko-terzić-magna-seati… · global...

Documents