Making Headlines
When you make outstanding products, you make news.
Mario Chaves, our Vice President, Costa Rica Operations, recently spoke with Executive Forecast about AVNA and the state of the manufacturing industry. Read the interview below or see the entire piece on Executive Forecast’s website.
MC: US-based AVNA INC. opened its Costa Rica facility 13 years ago with only five people and a big dream. Today, we’re over 150 strong, with strong ambitions. We recently celebrated the opening of our new and expanded facility, and over the next three years, we plan to double the size of our team. My role has been about more than just building a manufacturing company from the beginning. It’s all about creating the right culture. We focus on growth, constant improvement, and empowering our people because when we invest in them, they move the company forward. We’ve created a place where talent can grow, and everyone feels part of something meaningful. It connects to our mission: improving lives, one part at a time.
We’re expanding our operations because the life science market in Costa Rica has been growing steadily, and it’s still gaining momentum. More and more medical device OEMs are coming into the country, and our main goal is to provide them the highest quality components and assemblies We’ve also been bringing in new technologies, which will create a need for more talent.
MC: We work with various technologies, including laser processing like laser cutting, welding, marking, and CNC machining, which covers CNC Swiss-type lathes, CNC milling, and CNC lathes. We also offer stamping and plastic insert molding. We recently introduced new technologies, like ECG grinding and guidewire processing. Additionally, our new facility will house clean rooms, which allow us to perform sub-assembly for our customers in a controlled, environment. These additions are part of the growth we’ve been driving over the past few months and years.
MC: Our rebranding took place in 2024, marking a turning point for us. It reflects how much the company has evolved. We started over 100 years ago as a small tool shop and gradually expanded, building on different technologies and skills. When we opened our facility here in Costa Rica, we mainly made small parts, spare parts, and basic components. Now, we’ve moved into more complex sub-assemblies and advanced manufacturing.
The rebranding was a way to better align ourselves with our current and future core market focus, the medical device industry. AVNA stands for “Advancing Innovation,” which captures exactly what we aim for: constantly innovating and bringing new ideas to our customers through our technologies. Before the rebranding, we served multiple industries, but with this shift, we decided to focus on the medical device sector.
MC: We’ve built a unique offering by integrating multiple technologies under one roof. Our goal is to provide a complete manufacturing solution for our customers. In the beginning, we focused on making individual parts. Eventually, we added welding as a capability to produce, pairs of parts that needed to be combined, which led us to laser processing. Then, when we saw the need for plastic components, we also brought that capability in-house. We’ve grown by following our customers’ needs. Today, we focus on being a trusted partner by offering complete solutions, not just parts. Customers come to AVNA because they know we can deliver much more than just a piece; we provide the whole solution.
MC: I see a lot of similarities between that and everyday life, especially in manufacturing. I’ve had training cycles where the journey was tough, but the race was amazing. Sometimes, I’ve prepared perfectly, but the marathon didn’t go as planned. Other times, like when I was ready to qualify for the Boston Marathon, an injury just a week before stopped me from even starting. Surprises and challenges pop up all the time. Some days feel like a tough run; you may not feel your best, but you must keep pushing forward. Whether it’s a fast or slow day, every effort moves you forward, and it all adds up over time. It also teaches resilience and sets an example for others. At AVNA, for instance, we encourage a healthy, active lifestyle. Every year, we participate in a race here in Costa Rica with distances of 10 and 21 kilometers. Around 50 employees and even some of their family members join us. It’s one more way we live out our mission of improving lives, starting from within the company.
MC: That’s something we have to embrace. If we don’t, we risk being left behind. We need to take full advantage of these advancements. We have already started integrating AI, particularly on the administrative side of the business, and the impact has been tremendous in terms of efficiency.
We’ve seen improvements on the manufacturing floor, especially in programming CNC machines. What previously took three to four hours to program can now be completed with AI-supported tools in five to seven minutes. We are actively exploring and adopting these new technologies because they fundamentally change how we think, operate, and manufacture.
MC: My proudest moment happened during the pandemic. Along with many leaders during this time, I made the difficult decision to reduce work hours to maintain a full staff. I remember spending the night before preparing myself emotionally, particularly thinking about those who earn the least in the company. When I delivered the message to the team, I did so with tears in my eyes.
After the meeting, one of our employees approached me and thanked me for finding a solution to keep everyone employed, and he assured me they would find ways to make it through. It was a humbling affirmation that I had built a supportive and dedicated team that sticks together no matter what. It’s still one of the most emotional and meaningful experiences I’ve had here. I’ve had many proud moments, but that one will always stay close to my heart.
MC: It has been an incredible and rewarding journey for us. In two years, as we celebrate our 15th anniversary, we will be even more robust, with greater integration of AI into our processes. However, at the core, there will always be our talented people, driving and reinforcing our purpose and mission: improving lives one part at a time. Change is happening faster than ever. Products are becoming smaller, smarter, and more personalized. We’re not just keeping up; we’re leading. We’ll keep innovating to find better solutions for our customers. This new building is a big milestone, but only the beginning.