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KION HQ in Germany, Manufacturing, IT solutions for manufacturing industry, KION Group | DXC Technology Customer Stories

IT solutions for Manufacturing

Smart Factory platforms, sustainability solutions, predictive maintenance and quality analytics—all powered by IoT and AI.


Coal plant and conveyor belt at dusk, Cloud ERP for manufacturing, Whitehaven | DXC Technology Customer Stories
Whitehaven

Cloud ERP system streamlines processes and drives productivity



Hand holding glass bottle against blue sky and bright sun, software solutions for manufacturing industry, O-I Glass | DXC Technology Customer Stories
O-I Glass

IT costs cut by 35%, enabling investment in modernization


Female factory workers quality testing GPI printer cartridges, IT services for manufacturing companies, GPI | DXC Technology Customer Stories
GPI

SAP upgrade delivers 20% faster data analysis





 If scaling in the form of a triple CPU count is needed tomorrow, it can be done within 12 hours. In the past, it would typically take up to 12 weeks to procure, deliver, install and commission the hardware. Today, it’s like flipping a switch. ”

 

Hansjörg Heinrich
VP Global IT Infrastructure Services, KION Group

KION Group lowers costs and improves scalability with applications on Microsoft Azure cloud

 



The opportunity

Manufacturers are under pressure to update legacy systems and adopt intelligent, automated processes to drive innovation and business growth—while at the same time cutting costs, reducing inefficiencies, building greater resilience and ensuring compliance with current sustainability regulations. 

How DXC helps

With over 45 years of manufacturing expertise, we modernize operations and business IT, helping manufacturers reduce costs, improve quality and strengthen resilience. Our proprietary sustainability solutions maintain compliance, material traceability and circularity. This combination makes DXC the trusted partner for manufacturers ready to innovate at scale.

4+ million
plant production points managed
55% improvement
in on-time delivery for a munitions factory
300+
mission-critical environments managed
2,000 experts
in IT/OT infrastructure and manufacturing IT solutions




Why DXC for manufacturing

DXC delivers IT services for manufacturing that bring transformation to life for global industry leaders. Our modular, cloud-native platforms and Smart Factory solutions enable connected, automated and intelligent operations. Advanced analytics drive predictive maintenance and performance insights. Embedded regulatory support simplifies compliance, while end-to-end connectivity and integrated cybersecurity safeguard every stage of the value chain. Together, these capabilities provide manufacturers with the agility, security and operational visibility needed to compete in a rapidly evolving market.

IT/OT

Integrating IT and OT seamlessly enables real-time visibility, predictive maintenance and agile manufacturing.

Data-driven Decision-making

Using data to infom strategic business decisions optimizes production, reduces downtime, enhances demand-driven supply chain management, and improves quality.

Smart Factory

Smart factory solutions and predictive analytics reduce operational costs.

Digital Frameworks

Proven frameworks and IP-based accelerators designed for the manufacturing industry reduce implementation time for faster ROI.

AI-enabled Regulatory Compliance 

Intelligent monitoring and reporting enable energy-efficient operations and ensure regulatory compliance.

Security

End-to-end cybersecurity frameworks deliver robust protection.

Let's get started on driving business outcomes





DXC Manufacturing IT solutions

Tablet showing digital rendering of engine prototype, Smart Factory solutions | DXC Technology

Smart Manufacturing

The smart approach to digital transformation integrates AI, machine learning, advanced analytics and IoT manufacturing solutions to digitally transform the industry for more efficient business operations, predictive maintenance, and data usage for strategic decision-making.

Two designers reviewing material data system in Smart Factory, sustainable manufacturing solutions | DXC Technology

Sustainability & Circularity

Our proprietary MaCS, IMDS and CDX solutions ensure consistent, secure data exchange across the material declaration chain; support automated compliance reporting; enable real-time, multi-stakeholder coordination; provide transparency, traceability and analytics; and integrate with enterprise systems to create a seamless digital thread.

Two industrial engineers reviewing product design, supply chain management solution | DXC Technology

Manufacturing Operations Consulting

Monitor and schedule shop floor processes in real-time, and improve data synchronization, collection and traceability with Manufacturing Execution Systems (MES) and Product Lifecycle Management (PLM) consulting services and solutions—to design and develop new products more quickly.

Technicians in smart factory lab, AI solutions for manufacturing | DXC Technology

Business IT & Modernization

Adapt to Industry 4.0 and drive sustainable growth using enterprise applications that deliver enhanced operational efficiency, streamline processes and improve data-driven decision-making. Using the DXC Modernization Studio accelerator to upgrade and simplify your environment, you’ll empower faster change and reduce complexity.  




Manufacturing insights

Who do you trust? In manufacturing, the answer is no one

Manufacturing is the most targeted industry for ransomware. Enter Zero Trust: a security framework built on the principle of “never trust, always verify.”

The road to smart manufacturing

Russell Duggan-Rees, global chief technologist, Smart Manufacturing, explains how manufacturers can use next-gen Industry 4.0 technology to improve production, supply chain, logistics and KPIs.

Sustainability is AI’s new frontier for auto and manufacturing companies

Automakers can pioneer the future by using AI to embed sustainability decisions into their business.



Your future starts now

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Frequently asked questions about DXC 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.