Thank You for Joining Our Live Webinar with Mexico Industry!
On April 29th, 2025, our team of XO expert consultants had the pleasure of hosting a live webinar in collaboration with Mexico Industry. The session, held in Spanish, brought valuable insights to industry professionals across Mexico and beyond.
Led by our Director of Mexico Operations, Steven Bowler, alongside esteemed consultants Araceli Amezola and Irving Molina, the webinar explored a real-world case study involving a Tier 1 automotive client in Mexico. Attendees gained firsthand knowledge of how our team addressed and resolved significant operational challenges, showcasing strategies that drive efficiency and deliver measurable results.
If you missed it or would like to revisit the content, you can read the case below or access the recording via YouTube.
Transforming Supply Chain Resilience:
A Case Study in Automotive Manufacturing Excellence
In the fast-paced world of automotive manufacturing, supply chain disruptions can bring production to a grinding halt, jeopardizing deadlines, customer relationships, and profitability. When a Tier 1 automotive supplier of interior and exterior components in Mexico encountered significant operational challenges, they turned to Crossover Solutions, a global manufacturing consulting services firm renowned for its expertise in operational performance and supply chain optimization. The result? A rapid, impactful turnaround that
not only stabilized the supplier’s operations but also earned praise from their customer—an automotive OEM—as a potential industry model for addressing major manufacturing challenges.
The supplier was grappling a cascade of issues that threatened its ability to deliver upon commitments. Internal material shortages disrupted production schedules, creating a ripple effect of delays. Unclear cost responsibilities between the client and vendors led to financial disputes and logistical bottlenecks. High freight costs and excess inventory further strained the company’s bottom line, while inefficiencies in warehouse visualization and material flow compounded the chaos on the shop floor. With a critical product launch on the horizon, the supplier needed swift, decisive action to stabilize performance and ensure success.
Crossover Solutions promptly deployed a specialized team to step in and tackle the challenge head-on. Leveraging their expertise in Operational Performance Stabilization, Supply Chain Risk Management, and Targeted Performance Improvement Initiatives, the team conducted a comprehensive assessment of the supplier’s operations. They identified key risks in the supply chain, pinpointed logistics inefficiencies, and reimagined shop floor processes to restore stability. Warehouse visualization was overhauled, and material flow plans were redesigned to enhance visibility and streamline production. The goal was clear: to transform a struggling operation into a resilient, efficient system capable of meeting customer demands.
The improvements were immediate and transformative. Within the first month, Crossover Solutions delivered measurable results that redefined the supplier’s operational capabilities. Manufacturing throughput surged, enabling a 28% increase in monthly sales of pieces sold. Shipping efficiency improved dramatically, with a sustained 34% increase in weekly parts shipped. Past due orders—a persistent thorn in the supplier’s side—plummeted by 86%, dropping from 19,000 pieces to just 3,000. Financial pressures eased as expedited freight costs shrank from $1.8 million to $200,000 in the first month alone. The reorganized shop floor layout enhanced material flow and visibility, while strengthened vendor collaboration mitigated supply chain risks.
These numbers tell a story of rapid stabilization and sustainable growth. The supplier not only met its immediate production goals but also positioned itself for long-term success, ensuring a successful product launch for its OEM customer. The feedback from the customer was unequivocal: they praised Crossover Solutions’ intervention as a potential blueprint for the industry, a testament to the firm’s ability to deliver results under pressure.
Q&A Period Recap
We sincerely appreciate everyone who joined us for this insightful and engaging session. The Q&A portion at the end sparked some thoughtful questions from the audience which are captured below.
In the case of spare parts that are not common and, therefore, their manufacturing is not for immediate delivery, what can be done without increasing the warehouse value or avoiding obsolescence?
To manage uncommon spare parts without increasing warehouse value or risking obsolescence, we integrate them into production planning based on client needs, negotiated timelines, and historical data. Many planners overlook spare parts, yet they’re critical—especially in industries like automotive, where delays can directly impact customers. I typically analyze forecasts and historical trends to classify parts as high, medium, or low runners. High runners are stocked and prepped for quick shipping, while low runners are not pre-produced to avoid unnecessary inventory and disruption. This strategic approach balances availability, cost, and risk of obsolescence.
How do you handle workers’ reluctance to implement changes and break the paradigms they’ve been working with?
To overcome workers’ reluctance to change, the first step is helping them recognize that their current way of working isn’t sustainable—highlighting issues like constant client calls, weekend work, or late-night meetings as signs that change is needed. Then, we demonstrate that change is possible by leading by example—showing how structured communication, proper preparation, and visible results can transform operations. It’s also critical to have strong support from management, as their backing greatly improves team buy-in. Most importantly, we work side-by-side with the teams, not from a distance, proving through action—not just advice—that improvements are both achievable and practical.
At what point do you consider your consulting intervention to be complete?
A consulting intervention is considered complete when the operation stabilizes—there are no past-due orders, shipments are consistent, and the client’s team independently manages operations and communication. Key signs include a sustained OI above 85–90%, reduced or eliminated weekend overtime, and a return to a standard five- or six-day workweek. Our goal is not long-term presence but effective recovery and empowerment. As stability returns, we gradually reduce our involvement, leaving only minimal support to ensure the improvements hold and the client no longer needs external guidance to maintain performance.
Thank you for being part of the conversation shaping the future of operations in Mexico. Stay tuned for more events by following us on LinkedIn.
About Crossover Solutions:
Crossover Solutions is a leading manufacturing consultancy firm specializing in providing comprehensive manufacturing and management consulting services to clients across the globe. We deliver innovative solutions that enhance operational efficiency, drive growth, and optimize performance. Our team of leaders and experts combines deep industry knowledge with strategic thinking to empower organizations to thrive in today’s competitive landscape.