Build World-Class Factories. Achieve Global Benchmarks.
We combine decades of hands-on industrial plant leadership with structured execution cycles to deliver sustainable unit cost drops and lead time compression.
Cost Reduction & Productivity Improvement
High-margin operations are built on physical efficiency. We analyze floor layouts, machine balancing metrics, and setup changeovers to optimize output rates without adding headcount.
- Process flow optimization and line balancing
- Energy, material yield, and spatial footprint scaling
- Headcount productivity optimization without impact to morale
Lead Time & Alignment Improvement
Compressed cycle times free up working capital. We employ flow improvements inspired by the Theory of Constraints (TOC) to systematically remove batch waiting times, internal transfer losses, and inbound-to-outbound bottlenecks.
- Theory of Constraints (TOC) style queue control
- Alignment across inbound parts, production queues, and dispatch
- Systematic elimination of queue transit delays
Quality Systems & Certifications
We help manufacturers satisfy critical aerospace and automotive standards. We build audit readiness, configure zero-defect line gates, establish reliability labs, and stabilize process capability (Cp/Cpk indices).
- Audit preparedness for AS 9100D and IATF 16949 standards
- Zero-defect loops and local quality clinic installations
- Process capability (Cp/Cpk) monitoring and lab planning
Factory Set-up & Technology Selection
Avoid expensive asset selection errors. We bring direct expertise setting up complex machinery, including free-form lens labs, CNC lines, automated stamping presses, SMT lines, and large-scale eyewear framing lines.
- Greenfield plant designs and assembly layouts
- Machinery selection: Makino/Deckel Maho CNCs, SMT arrays
- Metal framings, precision injection molding, and stamping lines
Vendor Development & Supplier Ecosystems
A plant is only as stable as its supplier network. We establish captive supplier clusters (e.g. plating, tooling, surface treatments) and run structured qualification, auditing, and cost-modeling programs.
- Captive ecosystem building (tooling, surface treatment, plating)
- Technology introduction (e.g., Metal Injection Molding - MIM)
- Supplier qualification, should-cost modeling, and audit maps
Bridging the Gap Between Design and Shop-Floor Reality
Many manufacturing operations struggle with escalating unit costs, slow throughput speeds, and high scrap rates. Physical bottlenecks, unoptimized machinery cycle times, and setup changeover delays block factories from satisfying demand and freeze vital capital. These on-the-ground problems cannot be solved with generic strategy frameworks or high-level slide decks.
Furthermore, complying with international quality standards like AS9100D for aerospace and IATF 16949 for automotive requires disciplined compliance frameworks. Without hands-on practitioners to audit floor layouts, balance assembly lines, and build stable supplier networks, companies suffer from material margin dilution and missed deliveries.
Decisive Audits and Zero-Defect Local Quality Controls
We begin with a physical shop-floor diagnostic. By studying actual part flows, machine cycle times, and tool setups, we identify immediate constraint areas. Using Theory of Constraints (TOC) and Lean practices, we re-balance production lines, compress queue times, and install localized quality clinics to catch anomalies at source.
We also work to construct stable, captive vendor networks (tooling, surface treatments, plating) and prepare your organization for aerospace and automotive audits. Our approach is entirely operational: we work alongside your plant teams to build sustainable, zero-defect setups.
Key Deliverables
- Detailed value stream maps (VSM) and shop-floor constraint logs.
- Process line-balancing layouts and optimized setup schedules.
- Captive vendor evaluation playbooks and cost templates.
- Quality clinic audit sheets and Cp/Cpk monitoring frameworks.
Expected Outcomes
- 15-30% reduction in manufacturing unit costs.
- 25-50% compression of production cycle and queue lead times.
- 99.2% first-pass quality yield and guaranteed compliance audits.
- Stable, audited local supplier ecosystems for critical components.
Practice FAQs
How does Mexto identify shop-floor constraints?
We perform physical walkthroughs, time studies, and machine queue audits to identify the specific processes throttling your overall factory throughput.
Do you assist with AS9100D and IATF 16949 certifications?
Yes. We run pre-audit mock diagnostics, establish process capability (Cp/Cpk) metrics, and build localized quality clinics to guarantee audit readiness.
What machinery setups do your consultants support?
We have direct experience implementing setups for multi-axis CNC machines (Makino, Deckel Maho), SMT assembly arrays, automated stamping, and eyewear labs.
How long does it take to establish a vendor ecosystem?
Typically 8-12 weeks. We conduct cost modeling, technical audits, and supplier training to establish a stable local cluster of captive suppliers.
Sectors Serviced In This Practice
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