Client Success Story

Global Tech Leader Saves Millions Annually, Unifies Production and Distribution

Industry: Manufacturing & Distribution

Solution: Dynamics 365 Supply Chain Management, Advanced Warehousing, & MCA Connect Fixed Interval Scheduling

Introduction

For over 17 years, one of the world’s most recognized technology brands has relied (and continues to rely) on MCA Connect as a key partner in its supply chain evolution. At the time, the company was selling PCs and laptops directly to consumers, custom assembling each unit to buyer specs. The build-to-order model gave customers flexibility, but it came with major operational complexity.

This direct-to-consumer, configure-to-order (CTO) computing model pioneered an entire tech segment and fueled business growth. However, building a brand based on custom configuration and low prices carried a unique set of manufacturing and distribution challenges.

Challenge

As part of its high-volume, high-variability, configure-to-order (CTO) model, the company had six global manufacturing facilities, each operating differently. Every factory relied on its own unique process to produce the same products, and each had its own massive IT footprint — up to 600 physical servers onsite — and over 70 custom applications running operations.

As the global PC market moved away from the traditional configure-to-order (CTO) model toward standardized products and faster fulfillment, the company’s complex internal processes became increasingly risky.

Beyond shop floor complexity, every plant relied on manual processes to move and replenish materials. Each assembly line had a dedicated material coordinator manually calling for components, leading to delays, high carrying costs, and inefficiencies across vendor-managed inventory warehouses.

To stay ahead, the company partnered with MCA Connect to:

Create a single global operating system built on lean principles
Simplify and rationalize global IT infrastructure
Standardize processes across global manufacturing & distribution sites
Transform operations with real-time visibility and just-in-time delivery

Solution

The transformation hinged on three core components: Microsoft Dynamics 365, MCA Connect’s Fixed Interval Scheduling (FIS), and Advanced Warehousing.

MCA Connect led the global rollout of Dynamics 365 as the company’s core Manufacturing Execution System (MES) and Advanced Warehousing solution, replacing fragmented legacy systems across six distinct factories. This shift unified processes, reduced IT complexity, and created a single global operating model based on lean principles and real-time visibility.

But system unification alone wasn’t enough. As the company scaled and complexity grew, especially after acquiring a major enterprise storage manufacturer, it needed a smarter way to plan, move, and replenish materials. The new division brought high waste, limited visibility, and outdated scheduling. Meanwhile, AI, robotics, and automation were driving rapid changes in hardware complexity, particularly in building advanced AI servers.

FIS addressed production challenges, replacing ad hoc planning with structured, repeatable intervals that eliminated partial builds, reduced congestion on the shop floor, and aligned output with actual demand. At the same time, Advanced Warehousing automated material flow and replenishment.

Instead of relying on manual calls for components, the system evaluated whether parts were already at the line, in a mezzanine, or in vendor-managed stock. It pulled from the most cost-effective location first, ensuring company-owned inventory was consumed before drawing on supplier reserves. Mobile WMS apps further accelerated replenishment between fixed, cross-dock, and line locations, sequencing materials in short cycles.

Because each plant operated differently, MCA Connect worked with local teams to design custom location directives for every line. These directives determined sourcing priorities and supported complex scenarios, such as multiple “supermarkets” of the same material feeding different lines. This shift not only replaced dozens of manual material coordinators but also cut replenishment windows from 48+ hours to roughly six, freeing millions in working capital and slashing inventory carrying costs.

With Dynamics 365 as the digital backbone and FIS driving production precision, the company gained the ability to build any product in any facility with speed, consistency, and control. It can now shift production to meet trade fluctuations, support new product launches, and scale intelligently without increasing waste or overhead.

Results

Over more than a decade of collaboration, MCA Connect helped the company not just modernize its operations but turn manufacturing and distribution into a competitive advantage. Together, they redefined how global facilities operate, scale, and respond to change.

Key outcomes include:

75% reduction in IT footprint, enabling faster updates, lower maintenance, and less physical infrastructure across facilities
40% drop in IT support costs, totaling roughly $50 million in savings
62% reduction in non-value-added activity, streamlining workflows, and eliminating waste
50% reduction in labor costs and a 33% drop in overtime, driven by more efficient scheduling and process automation
Near-zero plant downtime, even amid major system rollouts and production model changes
Millions saved annually in labor, real estate, and tariff-related costs through smarter global operations
Reduced replenishment window from 48+ hours to ~6 hours.
Cut inventory carrying time from 3.5 days to 6 hours, freeing up millions in working capital.
Reduced material handling transactions by creating “supermarkets” and enabling direct supplier-to-line replenishment.
Eliminated the need for 40 manual material coordinators per plant across 10 plants.
Consolidated vendor and company-owned inventory into a single managed flow, optimizing what’s already owned before pulling new supply.
Delivered millions in savings from lower carrying costs, freed cash flow, and reduced wasted movements.

The company also consolidated 17 dispersed product lines into one single, lean manufacturing line, freeing up valuable space and creating capacity for next-generation builds like AI servers.

With FIS and Dynamics 365 in place across 10 global plants (and expanding), the company now plans production and procurement in hours instead of days, scales with demand, and avoids costly overbuilds.

These strategic and technical approaches continue to pay off financially. According to their 2025 10K report, the company reported:

$95.6 billion in total revenue, an 8% year-over-year increase
$6.2 billion in operating income, up 15%
$4.59 billion in net income, a 43% jump over the previous year
Record diluted EPS of $6.38, up 39%

Its IT infrastructure arm — home to its AI and enterprise product lines — grew revenue to $43.6 billion, up 29% year-over-year, with server and networking revenue alone up 37% in Q4.

From the shop floor to the balance sheet, the company isn’t just operating better… it’s built to outpace change, cut costs at scale, and lead the future of global supply chain.

About MCA Connect

Always industry-first, we deliver tailored strategies and leading-edge Microsoft solutions to help businesses succeed. We modernize supply chains end-to-end through:

Manufacturing and distribution strategic consulting
Data strategy and consolidation
Process optimization and automation
AI and advanced decision-making
Business application implementation

If you have a supply chain, we have the deep industry expertise to serve you.

Need help solving a difficult challenge? Want to modernize your business? Let’s talk!