IT solutions for Manufacturing

IT departments in manufacturing companies encounter unique challenges when it comes to smart manufacturing. We recommend an end-to-end approach that blends Industry 4.0 innovation with deep IT and operational technology expertise. We’ve designed our Smart Manufacturing portfolio for flexibility — whether you are launching a small-scale pilot or executing a global, multi-factory rollout. You need solutions that grow with your business, that reduce your risk and deliver measurable results quickly. Leveraging our market-leading capabilities in industrial IoT, data analytics, AI, OT security, and accelerator platforms, we can bring results up to six times faster than industry norms, cutting time-to-value and costs.

We manage 300+ mission-critical manufacturing environments, with successful Smart Factory implementations across multiple global sites. We have 60+ global Smart Manufacturing customers, and 55% improved on-time delivery synchronizing customers operations, workforce and materials.

Here are just some of our successes with Smart Manufacturing customers:

• Global titanium supplier: We eliminated $8.7M per quarter in government fines for non-delivery, and freed up $151M of capital using our Industrial IoT and Data Analytics services.
• Munitions factory: For this high-production, volume-lite manufacturer, we delivered 20% overall equipment effectiveness improvement by using our entire Smart Factory portfolio; improved forecasting accuracy by 70%; and significantly reduced the time spent searching for 10,000 tools and equipment in 46 buildings over a 5km site using our Connected Asset solutions.
• Large truck assembly company: Implementing our MACS solution for measuring end-to-end sustainability materials analysis, we enabled the company to gain control of 155,000 material data sheets and fully automated its MDS process for a maximum wait time of just 1 minute for a complex, 1-million-row Excel report.
• Product manufacturer: Moving the company to business outcome-oriented application management services resulted in a 24% YOY reduction in incident volumes and a >99.9% improvement in business process health.

Yes! Here’s one example: At DXC, we had been able to detect scratches on a car in a manufacturing line using computer vision models — and, as a result, reduce the return from dealers. That said, we could not get beyond 84 percent accuracy as there were not many images for edge cases (such as a scratch on a curved surface). Through multimodal generative AI, we generated new images and retrained the computer vision model, which increased the efficacy of the existing computer-vision model by three percent. 

This year, we introduced DXC AI Workbench, a generative AI offering which combines consulting, engineering and secure enterprise services to help businesses worldwide integrate and scale responsible AI into their operations. With our new AI Workbench offering, DXC is delivering a pre-built scalable solution with necessary safeguards and governance for secure deployment.

DXC's manufacturing industry software solutions embed AI and machine learning to reduce scrap and improve quality across manufacturing operations. Our Smart Factory platforms integrate computer vision, predictive analytics and quality monitoring tools to detect defects early, optimize processes and enhance product consistency. By analysing real-time data from sensors and machines, our AI models identify patterns that lead to waste or quality issues, which enables proactive adjustments and, in turn, reduces rework and material loss. Manufacturers benefit from improved overall equipment effectiveness (OEE), lower costs and faster time-to-market. DXC’s AI-powered solutions are scalable and secure, supported by 2,000+ experts in IT/OT infrastructure. Whether you're digitizing inspection workflows or embedding AI into production lines, we help you achieve measurable improvements in quality and efficiency.

Absolutely. DXC provides comprehensive Manufacturing Execution Systems (MES) and Product Lifecycle Management (PLM) modernization services. We offer advisory, architecture and operations support to help manufacturers upgrade legacy systems and align with Industry 4.0 standards. Our solutions enable real-time monitoring and scheduling of shop floor processes, improve data collection and traceability, and accelerate product design and development. By integrating MES and PLM with cloud-native platforms, DXC enhances collaboration, data synchronisation and decision-making across the value chain. Using the DXC Modernization Studio accelerator, we simplify complex environments and empower faster change. Our long-term support for leading OEMs and Tier 1 suppliers demonstrates our ability to deliver resilient, scalable and future-ready MES/PLM systems.

DXC helps manufacturers comply with sustainability regulations such as End-of-Life Vehicles (ELV) and Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) through our proprietary solutions such as MaCS, IMDS and CDX. These platforms automate compliance reporting, enable secure data exchange across the material declaration chain, and provide real-time coordination among stakeholders. They support traceability, transparency and analytics, integrating seamlessly with enterprise systems to create a digital thread from design to disposal. Our sustainability and circularity solutions ensure that manufacturers meet environmental standards while improving operational efficiency. DXC’s tools simplify regulatory workflows and reduce the cost and complexity of compliance. With embedded AI capabilities, we also help clients embed sustainability into strategic decision-making.

DXC enables secure, scalable machine connectivity across large industrial sites through our Industrial Connectivity and IT/OT Security solutions. We deploy private 5G networks, edge computing and modular IoT platforms to ensure seamless integration of operational technology with enterprise IT systems. Our DXC Signal Private 5G solution transforms network strategy, reducing latency and downtime while increasing productivity and safety. It supports thousands of concurrent connections across vast facilities, enabling real-time data exchange and remote monitoring. Combined with edge-to-cloud integration, manufacturers gain full visibility and control over distributed assets. Security is embedded at every layer. DXC’s Zero Trust cybersecurity frameworks protect both physical and digital assets, ensuring compliance with industry regulations and safeguarding against ransomware and other threats. Our IT/OT security experts deliver robust protection, enabling resilient factories that can scale securely.

Yes. DXC delivers predictive maintenance and real-time analytics as core components of our Smart Factory solutions. By integrating IoT, AI and machine learning across manufacturing environments, we enable continuous monitoring of equipment health, performance and utilization. This allows manufacturers to anticipate failures before they occur, reduce unplanned downtime and optimize maintenance schedules for cost efficiency. Our advanced analytics platforms provide real-time visibility into operations, empowering data-driven decision-making across production, supply chain and quality control. With over 4 million plant production points managed globally and 2,000+ experts in IT/OT infrastructure, DXC ensures scalable, secure and intelligent analytics deployment. Clients benefit from faster root cause analysis, improved OEE and enhanced responsiveness to changing demand. Whether you're modernizing legacy systems or implementing edge-to-cloud integration, DXC’s predictive analytics help you reduce scrap, improve quality and drive operational resilience.