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Case Study

From Blind Spots to Breakthroughs

How Magna Sterling Heights Improved OEE by 20%+ by Turning Downtime into Actionable Insight

Client

Industry:

Automotive Manufacturing

Built-In Value:

Real-Time Visibility

Machines
Connected:

Assembly and presses

Reading time:

~2 minutes

Overview

Turning Downtime into Actionable Insight

As part of Magna’s global Powertrain group, the Sterling Heights plant plays a critical role in high-precision automotive manufacturing.


But like many plants, they struggled with one core issue: they had data, but not insight, and adoption on the shop floor was low. 


That changed when they deployed Shoplogix in May 2024.

Quick Snapshot

Before
  • Limited reporting and poor adoption with other systems
  • Little visibility into unplanned downtime causes
  • Improvement initiatives based on assumptions
How
  • Real-time OEE, downtime capture, and operator-driven data
  • Simple, operator-friendly downtime reason capture
  • Data-driven prioritization of top losses
After
  • 20%+ OEE improvement
  • 85%+ adoption of downtime reasons
  • Sustained performance gains
The Challenge

“We had a system, but no one was really using it.”

Before Shoplogix, the plant relied on another system, but the solution suffered from: Poor shopfloor adoption , limited reporting capabilities and minimal operator input on downtime causes As a result, leadership lacked confidence in the data, and improvement initiatives were often reactive instead of strategic.

What That Looked Like on the Plant Floor

Disconnected data equals disconnected teams

Operators weren’t consistently entering downtime reasons

Continuous improvement efforts stalled due to unclear root causes

Supervisors couldn’t trust reports to prioritize issues

Valuable production time was lost to unplanned downtime with no explanation

The Shoplogix Solution

Simple for operators. Powerful for leaders.

Shoplogix was deployed in May 2024 with a focus on:

Real-time OEE visibility

High-adoption downtime reason capture

Operator-friendly interfaces designed for the plant floor

Clear, actionable analytics for leadership

Unlike the previous system, Shoplogix didn’t just collect data; it made it usable, visible, and trusted across teams.

The Real Results

Measurable improvement. Sustained momentum.

Since deployment, Magna Sterling Heights has achieved:

20%+ improvement in OEE

85%+ consistent capture of unplanned downtime reasons

Clear identification of top downtime drivers

Faster prioritization of improvement opportunities

Strong alignment between operators, supervisors, and leadership

The biggest difference? Good data that people actually use.

Key Takeaways

Adoption matters more than dashboards

Operator input is critical to reducing unplanned downtime

Real-time visibility enables smarter prioritization

Trusted data drives continuous improvement, not guesswork

Why It Matters for Manufacturers

You can’t fix what you can’t see, and you can’t see what no one uses.

This case proves that:

  • Technology alone isn’t enough
  • Ease of use drives adoption
  • Adoption drives insight
  • Insight drives results


Shoplogix bridges the gap between the shop floor and leadership, turning everyday production data into measurable performance gains.

Looking Ahead

Next step: unlocking labor efficiency

With strong momentum in OEE and downtime visibility, the next phase at Magna Sterling Heights includes deploying Shoplogix’s Labor Model to:

Understand true labor efficiency

See which operators run which parts most effectively

Identify hidden training opportunities

Optimize staffing decisions with real data, not assumptions

Ready to get started?

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