What We Take Responsibility For

Plant Setup (Greenfield & Brownfield)

From empty floor to stable production.

Plant setup decisions define performance for years. Poor layouts, rushed capacity planning, and fragmented execution create permanent inefficiencies.

Mecwerx provides end-to-end plant setup support, owning engineering and execution from concept to stable operations.

What Plant Setup Support Means

Plant setup is not consulting.
It is engineering + execution + accountability.

We convert business intent into a working production system and stay responsible until output is stable.

Scope of Plant Setup

Planning & Engineering
Capacity and throughput definition · Process flow and layout planning · Space utilisation and expansion readiness · Manpower and workflow alignment

System Execution
Production lines and workstations · Custom machines, SPMs, tooling and fixtures · Material flow and storage systems

Installation & Commissioning
Installation sequencing and coordination · Dry runs, trials and ramp-up

Readiness & Training
SOPs and documentation · Operator, supervisor and maintenance training

Greenfield & Brownfield

Greenfield
Right-first setup from a bare floor · Faster startup with disciplined ramp-up

Brownfield
Capacity expansion without disrupting operations · Bottleneck removal and line re-engineering

Process Optimisation & Efficiency Improvement

Not all processes need fixing.
Only the ones that are limiting output.

Mecwerx analyses live production processes to identify losses, inefficiencies, and constraints that directly impact throughput, quality, and manpower utilisation.

Improvements are implemented only where they deliver measurable gains. If a process already works, we leave it untouched.

Scope

Process Analysis & Loss Identification
Cycle losses · Idle time · Rework · Constraint mapping

Throughput & Capacity Improvement
Bottleneck removal · Line balancing · Output stabilisation

Manpower & Method Optimisation
Work content alignment · Motion reduction · Skill utilisation

Quality & Process Stability
Variation control · Error reduction · Repeatability improvement

No theory. No cosmetic changes.
Only improvements that show up in daily production numbers.

Material Flow That Supports Production

Poor material movement silently destroys efficiency. We design production-aligned material flow systems — not warehouse showpieces.

Scope

Storage & Racking Systems
Designed for access speed, not storage density alone

Line-side Material Presentation
Right part, right quantity, right point of use

Internal Logistics & Movement Planning
Defined routes, handling logic, and movement discipline

Space Optimisation & Future Scalability
Layouts that work today and don’t block tomorrow

Designed for daily operations — not drawings.

Custom Machines, SPMs & Workstations

Standard machines solve standard problems.
Production rarely has standard problems.

Mecwerx designs and builds custom machines, SPMs, and workstations around specific process requirements — engineered for reliability, operator ease, and seamless integration into the production line.

If standard equipment doesn’t fit the process, we build what does.

Scope

Custom Machines & SPMs
Process-specific automation · Dedicated assembly and testing machines · Cycle-time driven design

Workstations & Ergonomic Design
Operator reach and posture optimisation · Error-proofing · Ease of maintenance

Mechanical, Electrical & Controls Integration
Sensors · Actuators · PLC logic · Safety systems

Line Integration & Stabilisation
Mechanical fitment · Electrical integration · Trials and fine-tuning

Built for production realities — not catalogue specs.

Training That Makes Plants Run Better

Training is not a course.
It is a performance stabiliser.

Mecwerx delivers training only where capability gaps impact production. This includes time study, motion study, 5S, visual management, capacity improvement, and lean implementation — only where they improve output.

What “Need-Based” Means

Training defined by the process
Built around actual equipment and workflows
Delivered on the shop floor
Measured by performance improvement

Training Scope

Operators
Safe operation · Standard work · Quality awareness · Basic troubleshooting · 5S discipline · Visual management adherence

Maintenance Teams
Preventive practices · Early fault identification · Breakdown reduction · Equipment care standards

Supervisors & Team Leads
Line control · Shift discipline · Loss handling and escalation · Time study & motion study · Capacity improvement · Lean implementation

Training supports execution.
It is never sold in isolation.

Installation, Commissioning & Validation

Where systems go live — or don’t go live at all.

Mecwerx takes complete ownership of installation, commissioning, and validation, aligned to real production targets — not theoretical specifications.

Correct sequencing and system integration
Structured trial runs for stable operations
Performance validated before sign-off

If a system isn’t production-ready, we don’t sign it off.

No soft launches. No temporary fixes.

Documentation & Post-Handover Support

Good documentation doesn’t sit in folders.
It keeps plants running after the project team leaves.

Mecwerx delivers clear, usable documentation and a structured handover to ensure a clean transition from project execution to daily operations.

We don’t disappear after commissioning. We stay involved to support production stability, problem-solving, and early operational challenges.

Scope

Line Layouts & System Documentation
As-built layouts · Process flow diagrams · Equipment integration details

Operating SOPs
Standard work · Start-up and shutdown procedures · Quality checkpoints

Equipment & Maintenance Manuals
Machine operation · Preventive maintenance · Troubleshooting guides

Electrical & Control Drawings
Electrical schematics · PLC I/O lists · Safety circuit documentation

Handover is complete only when operations are stable — not when documents are submitted.