Client Success Story
Global Technology Leader Saves Millions Annually, Consolidates 17 Plant Lines Through Supply Chain Modernization
Industry: Manufacturing
Solution: Dynamics 365 Supply Chain Management, MCA Connect’s Fixed Interval Scheduling
Introduction
In 2008, MCA Connect began working with one of the world’s most well-known technology brands. Founded in 1984, the company empowers countries, communities, and customers to use technology to realize their dreams.
At the time, the organization sold PCs and laptops directly to consumers, custom assembling each unit according to buyer specifications. However, building a brand based on custom configuration and low prices had unique challenges.
Challenge
As part of their high-volume, high variability, configure-to-order (CTO) model, the company had established its six global manufacturing facilities completely differently.
For example, each factory relied on different processes to produce the same products. Each facility also had a unique IT footprint with up to 600 physical servers onsite. And across facilities, operations relied on more than 70 highly customized applications to guide each unit through the factory and out the door. On top of that, the global PC market was shifting from the traditional CTO model towards standard product configurations.
Solution
Hybrid
Under the guidance of MCA Connect, the company rolled out Microsoft Dynamics to its six facilities around the world.
Acting as the company’s core Manufacturing Execution System, Dynamics allowed the company to streamline operations with a single, global business model using lean principles and industry best practices.
The company started with Dynamics AX, and over the years, upgraded to Dynamics 365 for Supply Chain Management.
An acquisition brings new challenges
In 2016, the technology giant acquired a well-known enterprise storage business. The acquired company struggled with large amounts of shop floor waste, costly, decades-old manufacturing processes, limited visibility into its production line, and an inefficient order scheduling process.
With the help of MCA Connect’s manufacturing experts, the enterprise storage company redesigned its production line. The division also implemented MCA Connect’s Fixed Interval Scheduling solution to optimize its order scheduling process and eliminate partially completed products sitting on the shop floor. With it, the acquired company gained greater visibility into its production line and the ability to make better business decisions.
Results
Over 14 years, MCA Connect enabled the well-known technology company and its acquired enterprise storage division to plan production and procurement in hours versus days. In addition to standardizing and streamlining global processes, the company also continuously enhanced and expanded systems to achieve:
Millions
saved
in annual labor, real estate costs,
and tariff avoidance
17 global plant lines consolidated
into one line capable of producing any product from any location in the world
75% reduction
of IT footprint
62% reduction
in non-value-add
50% reduction
in labor costs
Near 0
Reduction of plant downtime to
40% reduction
of IT support costs (about $50M in savings)
300% improvement
in cash flow
33% reduction
in overtime
2,190 inventory turns
per year, far surpassing the industry standard of 50-100 turns.
About MCA Connect
Through passion and deep industry expertise, MCA Connect® helps manufacturers succeed by unlocking innovation with actionable business insights. Our strategic solution and industry intelligence help manufacturers gain visibility, improve profitability, and achieve a competitive edge. Contact us today to learn how we can help solve your biggest manufacturing challenges.
