Case Studies

Magna Corporation

General Description

  • Magna’s Metal Forming plant in Bowling Green, KY reached out to TPT in order to perform efficiency improvements to their material handling department.
  • The two areas of focus were: better throughput of material, and cost savings by modeling a more efficient structure to the daily tasks of the employees.


  • Develop baseline time study to establish current manpower usage and delivery methodology.
  • Identify opportunities to increase throughput, reduce downtime due to late line feeds, and methodize the usage of the equipment.
  • Observe and analyze warehouse activities to improve organization, proper location of parts, and minimize repacking of parts between totes.


After implementing new processes and efficiency measures, Average annual savings totaled approximately $500,000

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