Amalia Ma - Director of Operational Improvement and Quality
Big Picture: MAFACT is how we drive world-class manufacturing. It’s a management system and a set of standards that reflect the image of our company.
Passion: It’s a great joy to me that MAFACT helps us to eliminate waste and gives Magna financial benefits, but the most exciting thing is watching teams work together and grow. I love teaching others and helping them develop.
Best Practice at Work: Our Cosma Shenyang division is a benchmark for applying the 5S tools – sort, set things in order, shine, standardize and sustain. Clean, organized divisions with well-trained people in charge of their operations
are critical today and for the Factory of the Future. With robots and automation, you will still need humans to maintain, operate and analyze data.
Best Practice at Home: I taught the 5S rules to my 10-year-old son Hafiz. He uses them to keep his room clean, even though I need to remind him sometimes.
Big Picture: MAFACT is a mindset. We want to provide value to our customers with the lowest cost, highest quality and shortest delivery time.
Passion: I like to problem-solve and figure out how to optimize a process or condition. The MAFACT principles allow you to think deeply about the micro-level of cost. We look at the final product and how it’s being processed from every step. If you ship a million parts, every cent of improvement counts. My role is to coach employees to see waste reduction opportunities and spread that knowledge in their divisions.
Best Practice at Work: 80% of Magna’s 24 powertrain divisions have adopted the U-shaped assembly line concept. It’s similar to a U-shaped bar with the bartender and the bottles on the inside. It’s a more flexible and
efficient setup with significant savings.
Best Practice at Home: Routine helps me to be productive, from waking up at the same time every day to walking the dog. I always challenge myself, even when I’m cooking noodles. How do I cook them in the shortest timeframe? What
can I do when the water is boiling?
Key Takeaway: MAFACT allows us to be a competitive, world-class manufacturing operation. It also speaks to the sustainability of Magna. By being competitive, it allows the company to last for generations.
Big Picture: MAFACT is a tool to help our employees be more successful and our divisions more profitable. By doing that, we attract new business and help make the business sustainable. It’s about job security, but it’s also about treating our resources properly and having a positive effect on the planet.
Passion: I started out as a quality engineer. I like helping people and solving problems. By teaching our employees to use the MAFACT tools, they can solve problems as well.
Best Practice at Work: We use MConnect, a database for idea sharing where everyone can access lessons learned and practices benchmarked at other plants. There’s a contest with a trophy called the MConnect Cup, where 34 divisions
compete every year based on number of ideas submitted and implemented, along with savings. It’s an incentive to use the system.
Best Practice at Home: Visual management is a big part of MAFACT training. Every time I drop my sons Jax and Beckett off at school, I notice the congested carpool lanes and think it would be so much better if I could redesign it. I have
not addressed this with the school administration yet, but I’ve been tempted to.
Key Takeaway: MAFACT is about helping our divisions grow and succeed. When you put the operational principles in place, it helps to prevent and solve issues.
Big Picture: MAFACT and sustainability go together. Both pursue a world-class approach for people, process and product. With this as our operational excellence guideline, it’s a way to envision our future and how we develop a business
that protects the planet, as we keep Magna as the right choice for investors, customers and employees.
Passion: I started on the shop floor and worked my way up to operations management and improvement. When I was a quality coordinator, I was invited to participate in a workshop where operators were allowed to speak about their ideas. That was the ‘aha’ moment that drove my career and education. The only place where we get consistent results is where things happen – at the shop floor. You must use the experience of everyone to continuously improve.
Best Practice at Work: Cosma Casting Poland used MAFACT to improve and turn around its business by involving people. For example, they invited me to train all of the division’s team leaders to create 100% of their standardized work. They understood what the production workers needed. Shop-floor involvement is critical.
Best Practice at Home: It’s not possible to split the mindset after doing this on a daily basis. I’ve become a data-driven person. I’m getting a new roof on my house and I know every single detail of the project and execution. I’m the same way with supermarket lists – really organized.
Key Takeaway: Our main goal is to have our people engaged, motivated and aligned. Doing the best for our business, investors, employees and customers. That’s what drives our operations. MAFACT empowers people to have great results.
Big Picture: MAFACT is a system that puts procedures and policies in place, and affects everything you do. When you dissect it, it’s very simple: Use common sense, communicate and understand the true problems.
Passion: I enjoy coaching individuals and preparing them for future opportunities. I’ve had hourly associates who became team leaders. One just got promoted to assistant general manager. With MAFACT and a background in lean manufacturing, you don’t need high levels of education. You need an open mind and the will to do better.
Best Practice at Work: At Integram Windsor Seating, we used MAFACT and lean manufacturing principles, and got a slamdunk in all categories, including health, safety, quality and cost savings. We tore out traditional assembly lines and went from a manual system to one using automated guided vehicles for production lines. It’s opening new opportunities and helping overall business.
Best Practice at Home: My family of 6, including four kids, is moving to a new house. We used 5S quality tools that are part of MAFACT to clean a messy closet filled with jackets, shoes, toys and cat food. Now, the closet is immaculate.
Key Takeaway: MAFACT keeps us competitive in a competitive world with current and new customers. MAFACT is listening, understanding and keeping it simple. Work with your peers. Understand their problems and fix them.
Best Practice at Work: MAFACT is always challenging us to make improvements in energy reduction and energy savings. Since the beginning of 2022, the Magna Steyr plant in Graz, Austria, is CO2 neutral, a sustainability achievement that was also driven by MAFACT. We are a big global company with so many ideas. It’s very easy to share best practices in all areas of expertise. If we are collaborative and work together, we will continue to improve our processes, technologies, procedures and methods, eliminate waste and use our resources effectively.
Best Practice at Home: I’m always trying to reduce energy consumption at home. I installed a heat pump and solar panels on the roof this spring, and I’m driving an electric vehicle. I consider these measures an investment in the future, especially for my eight-year-old daughter Helena.
Key Takeaway: There’s a connection between MAFACT, world-class manufacturing and moving forward for all. Everything is linked. It’s a great combination.
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