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
13 Manufacturing / Assembly
2Engineering / Product
Development / Sales
3,500 Employees
ASIA
59 Manufacturing / Assembly
23Engineering / Product
Development / Sales
22,775 Employees
EUROPE
117 Manufacturing / Assembly
50Engineering / Product
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
• 20,400 employees
• 58 mfg/assy facilities*
• 13 product development/
engineering/ sales centers
*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
• 8 product development/
engineering/ sales centers
ROOF SYSTEMS
Capabilities
• soft tops
• retractable hard tops
• textile folding roofs
• modular roofs
Global Footprint
• 2,050 employees
• 6 mfg/assy facilities
• 4 product development/
engineering/ sales centers
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
• 13,300 employees
• 41 mfg/assy facilities*
• 10 product development/
engineering/ sales centers*
*including Minority JVs
28.09.2017 Magna Seating Marko Terzić 3
Product Systems
Capabilities
• body systems
• chassis systems
• technology, engineering
& tooling systems
Global Footprint
• 44,450 employees
• 93 mfg/assy facilities*
• 21 product development/
engineering/ sales centers
* including Minority JVs & In Progress Facilities
BODY & CHASSIS
Capabilities
• automated driving systems
• secure connectivity
• electrification
Global Footprint
• 1,925 employees
• 6 mfg/assy facilities
• 11 product development/
engineering/ sales centers
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
• 11,700 employees
• 16 mfg/assy facilities
• 29 product development/
engineering/ sales centers
VEHICLE ENG & CONTRACT MFG
FUEL SYSTEMS
Capabilities
• GETRAG transmissions
• driveline systems
• fluid pressure & controls
• metal-forming solutions
• advanced engineering
Global Footprint
• 32,275 employees
• 54 mfg/assy facilities
• 30 product development/
engineering/ sales centers
POWERTRAIN
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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
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.
Magna Seating Marko Terzić
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.
Magna Seating Marko Terzić
8 Pillars
28.09.2017 Magna Seating Marko Terzić 11
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
28.09.2017 Magna Seating Marko Terzić 12
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
28.09.2017 Magna Seating Marko Terzić 13
• 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
28.09.2017 Magna Seating Marko Terzić 14
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
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!
28.09.2017 Magna Seating Marko Terzić 16
TOP KAIZENS – BROKEN SEAM
28.09.2017 Magna Seating Marko Terzić 17
Critical X 1
Critical X 2
Critical X 3
Critical X 4
TOP KAIZENS – PRODUCTION BACKLOG
28.09.2017 Magna Seating Marko Terzić 18
Problem: Production backlog
Critical X 1
Critical X 2
Critical X 3
Critical X 4
TOP KAIZENS – INVENTORY DISCREPANCIES
28.09.2017 Magna Seating Marko Terzić 19
Problem: Inventory discrepancies
Critical
X 1