Case Study

Automotive

Supporting the auto industry's first volume production of carbon fiber hoods for Cadillac's 2016 ATS-V and CTS-V high-performance models.

Background: Magna International Inc. is leading global automotive supplier with 306 manufacturing operations and 92 product development, engineering, and sales centers in 29 countries.

The Problem

New materials, such as carbon fiber, are finding new areas of application in the automotive industry. Carbon fiber's high strength and light weight help car makers meet their mileage, emissions, and safety objectives. As a key player in the industry, Magna is committed to supplying hoods using carbon fiber for Cadillac's V-series vehicles. Introducing new materials and processes is always a major challenge. There are variant materials and process factors, both for Magna and at its customer that must be considered and they typically interact. The combinations of factors can be bewildering.

The Solution

The project involved a team of experienced engineers who needed to sharpen some analytical skills and practices to move the project forward. Predictum provided specialized training and technical support in the area of design of experiments. We also provided a computer-based system to organize and link their activities using the "Plan-Do-Study-Act" format. This system enabled Magna to see both the forest and trees.

Working with the engineering team to sharpen analytical skills, complimented by a custom digital system to organize activities, resulted in large gains in operational performance and productivity.

The Benefit

Magna introduced the product on time and delivered the required volumes to the customer. Its team continues to use the practices they learned, which has contributed to substantial ongoing improvements in productivity and quality. Magna was recognized by JEC Americas for its innovations which came from this project.

News Release - Magna Wins 2016 JEC Americas Innovation Award

The Problem

Variant materials and process factors led to ambiguous results.

The Solution

Specialized training and technical support in the area of design of experiments.

The Benefit

Successful product delivery ongoing improvements in productivity and quality.