Client Success Story
Global Technology Leader Saves Millions Annually, Unifies Production with Flexible, High-Mix Capabilities
Industry: Manufacturing
Solution: Dynamics 365 Supply Chain Management & MCA Connect Fixed Interval Scheduling
Introduction
For over 15 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 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.
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 sites
- Transform operations with real-time visibility and just-in-time delivery
Solution
The transformation hinged on two core components: Microsoft Dynamics 365 and MCA Connect’s Fixed Interval Scheduling (FIS).
MCA Connect led the global rollout of Dynamics 365 as the company’s core Manufacturing Execution System (MES), 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 more intelligent way to plan and run production. 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 these challenges. It replaced ad hoc production planning with structured, repeatable intervals that eliminated partial builds, reduced congestion on the shop floor, and aligned output with actual demand. Combined with Dynamics 365, it created a fully integrated system connecting planning, execution, and feedback.
As the product mix expanded, FIS extended beyond the shop floor into warehouse and supply chain planning. What started as a production tool became a key driver of end-to-end operational efficiency.
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 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
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 manufacturing.
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!
