Andon · ToolCrib · OEE · Traceability
Custom manufacturing software development for U.S. manufacturers and the plants they run in Mexico. We build digital Andon systems, tool crib management, OEE monitoring and traceability around the way your lines actually work — from Mexicali, on the border, on U.S. Pacific time.
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−38% stoppage response timeBook a call with the team
01 — What we build
Most plants don't need a monolithic MES on day one. They need to stop losing minutes on line stoppages, stop chasing tools across shifts and finally trust their OEE numbers. We build the modules that solve those problems first, then connect them into one system.
01
One-touch alerts per station, live dashboards for supervisors, automatic escalation when nobody responds and a full log of every stoppage — so maintenance, quality and materials get called before the line backs up.
Alerts · Escalation · Response metrics
02
Kiosk-based loans and returns with QR codes, per-shift accountability, usage history per tool and shrinkage reports. The crib attendant stops keeping a notebook; you stop buying the same gauge twice.
QR · Kiosk · Audit trail
03
Availability, performance and quality captured per line and per shift, from machine signals or operator input, with downtime reasons your engineers can actually act on.
Downtime · Scrap · Throughput
04
Work orders, production counts, operator check-ins and shift handoffs on tablets and screens at the line, replacing paper travelers and whiteboards.
Work orders · Shifts · Counts
05
Lot, serial and operator genealogy from raw material to shipped part, so a customer complaint or audit becomes a query instead of a week of digging through binders.
Lots · Serials · Audits
06
Machine and sensor data over MQTT feeding real-time dashboards and alerts — the visibility you need without a heavyweight SCADA license.
MQTT · Gateways · Real-time
02 — Proof
Two manufacturing systems we designed, built and support. Client names stay confidential; the results don't. More in our case studies.
Manufacturing · 2025
A line-alert system for a 14-station plant. Each station has its own dashboard; unanswered alerts escalate automatically to supervisors, and every call is timed so management sees response times by station, shift and cause. It runs in the browser, so it is accessible from any internet-connected device — floor screens, tablets or a manager's phone.
Manufacturing · 2026
A touch kiosk on the floor where operators check tools in and out with QR codes. Every loan is tied to a shift and a responsible operator, so each tool carries a complete audit trail with its usage history, and shrinkage reports show where inventory is leaking. It eliminated the Excel sheets and radio calls the plant used to track tool loans.
03 — Custom vs packaged
Packaged MES suites are powerful, but they assume a plant that looks like the vendor's demo. If your escalation rules, stations or reports are specific — and in high-mix plants and maquiladoras they usually are — you end up paying for configuration consultants and workarounds. Custom software starts from your process and grows with it.
| Factor | Custom (Nexus) | Off-the-shelf MES | Excel & radios |
|---|---|---|---|
| Fit to your process | Built around your lines | You adapt to the product | Flexible, but fragile |
| Time to first value | One module at a time | Long, plant-wide rollout | Immediate, no visibility |
| Licensing | No per-seat license fees | Per seat / per site | None |
| Integration with ERP & machines | Built to your systems | Connectors, often paid | Manual re-typing |
| Real-time data & audit trail | Yes | Yes | No |
| Operator adoption | Screens designed for your floor | Generic UI, training-heavy | Familiar, error-prone |
04 — Plants in Mexico
If your company is headquartered in the U.S. and manufactures in Baja California, your software partner should be able to stand on both sides of that line. We are in Mexicali, minutes from the Calexico crossing and roughly two hours from San Diego.
That means we can walk your floor, sit with operators and supervisors in Spanish, then report to engineering and operations leadership in English — same day, same time zone. It is the nearshore model applied to the plant floor, and it is especially practical for teams in California running operations south of the border.
Discovery walks, go-live support and training happen at the plant, not over a grainy video call.
Interfaces in Spanish for the floor, documentation and dashboards in English for HQ.
Standups and reviews run live with your U.S. team, not on an overnight handoff.
USMCA proximity keeps agreements and invoicing straightforward for U.S. companies.
05 — How it works
Plant software fails when it is designed in a conference room. Ours starts on the floor and ships in small, testable pieces.
01
We map stations, roles, escalation paths and existing systems, and agree on the metric the first module must move.
02
Navigable prototypes of operator and supervisor screens, validated with the people who will use them.
03
Two-week sprints with real demos. Tests, code review and CI from day one, plus pilots on a single line.
04
Supervised deploy on the floor, operator training and ongoing support with 24/7 monitoring for critical systems.
A single, well-scoped module — an Andon or a tool crib — gets to a working pilot far faster than a plant-wide platform. Larger programs are phased line by line so production never waits on the software. You can engage us for a fixed-scope project or keep a dedicated development team that owns your plant systems long term.
Web dashboards in Next.js and React, APIs in Node.js or Laravel, data in PostgreSQL, machine telemetry over MQTT, deployed with Docker on AWS or on your plant servers. Need a rugged tablet or phone app for supervisors? We build those too in Flutter, Swift and Kotlin, alongside the rest of our custom software development work.
Next.js · React · Node.js · Laravel · PostgreSQL · MQTT · Docker · AWS
06 — FAQ
Off-the-shelf MES platforms are designed for a generic plant. Custom manufacturing software is built around your lines, stations and escalation rules, so operators adopt it faster and you only pay for the modules you actually use. It also integrates with the ERP, machines and spreadsheets you already have instead of forcing a rip-and-replace.
A digital Andon system replaces cords, lights and radios with a screen or button at each station. When an operator raises an alert, the right supervisor is notified, the call escalates automatically if nobody responds, and every event is logged so you can measure response times and stoppage causes.
Yes, where the equipment allows it. We use light SCADA and IoT patterns such as MQTT to read signals from machines, gateways and sensors, and combine them with operator input on the floor. For older equipment, operator-entered data and simple sensors are often enough to start measuring OEE.
Yes. We are based in Mexicali, Baja California, so we can visit plants in the region in person, work with Spanish-speaking operators and supervisors, and report to U.S. headquarters in English on U.S. Pacific time.
It depends on scope. A focused module such as an Andon or tool crib system reaches a first working release much sooner than a full shop floor platform, which we deliver in phases. We work in two-week sprints with real demos, so you see working software on the floor early.
We run a supervised deploy on the floor and stay on for ongoing support. For critical plant systems we offer 24/7 support and monitoring, and we keep improving the software as your lines, products and reports change.
07 — Contact
Describe your plant and the problem you want to fix first. We reply within 24 business hours with an initial proposal — no commitment required.
Planta Tijuana 1672, Mexicali, Baja California, 21170 · U.S. Pacific time
