How Mars Eliminated Hidden Energy Waste and Achieved 7x ROI with Real-Time Monitoring
Client
Industry:
Automotive
Reading time:
~4 minutes
Machines
Connected:
Magna International is one of the world’s leading automotive suppliers, operating complex, high-volume production environments where uptime is critical.
When maintenance and production systems don’t talk to each other, downtime becomes harder to detect, slower to resolve, and nearly impossible to optimize.
That was the reality for Magna, until they unified their operations with Shoplogix.
Magna was operating with two critical systems, Andon and CMMS, that functioned completely independently.
Operators struggled to escalate issues quickly
Work orders were created late, if at all
Critical metrics like MTTR and MTBF were difficult to control
Critical metrics like MTTR and MTBF were difficult to control
Maintenance teams lacked real-time visibility into machine failures
The result? Reactive maintenance and lost production time.
Connecting production and maintenance into one seamless, real-time workflow, Magna implemented:
Shoplogix Digital Andon to instantly trigger maintenance events
Fixit to streamline work order management
This created a closed-loop workflow between production and maintenance:
Operators trigger issues in real time
Work orders are automatically created and tracked
Maintenance teams respond faster with full visibility
Data flows seamlessly into reporting and continuous improvement
Most importantly, the system was easy to use, driving rapid adoption across the plant.
Measurable gains in uptime, adoption, and maintenance performance
+12% increase in availability
Faster work order creation and response times
15x increase in CMMS adoption (from ~4 users to 60+)
Improved technician utilization
Full visibility into: Mean Time to Repair (MTTR) ; Work order lifecycle ; Preventive maintenance completion rates
Magna also gained daily management reports, enabling structured, data-driven conversations around maintenance performance.
What top-performing plants do differently
Adoption drives impact → expanding access increased effectiveness
Integrating production + maintenance unlocks operational synergy
Simplicity is critical → ease of use led to rapid scaling across teams
Adoption drives impact → expanding access increased effectiveness
Turning maintenance into a competitive advantage, not a bottleneck
Most plants don’t struggle because they lack systems; they struggle because their systems don’t work together.
Shoplogix changes that.
By connecting production signals with maintenance execution, manufacturers can:
This is how manufacturers move from reactive firefighting to proactive performance at scale.
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Magna’s transformation wasn’t just about implementing new tools; it was about enabling faster decisions, stronger alignment between teams, and a more proactive approach to maintenance.
With Shoplogix, they didn’t just improve availability; they built a foundation for continuous improvement, where every issue is visible, every action is tracked, and every team is empowered to perform at their best.
That’s the difference between managing downtime and eliminating it.
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