IT/OT Cost Optimization for a Global Automotive Leader

ITOT Cost Optimization

Customer

IT/OT Cost optimization for a Global Automotive Leader
A multinational automotive manufacturer operating across multiple continents, managing complex production environments with deeply integrated IT and OT systems. With thousands of applications across plants, engineering units, and business functions, the organization faced rising operational costs, system complexity, and aging legacy platforms. The customer required a unified and scalable modernization approach to streamline their global technology landscape while maintaining the reliability of mission-critical automation.

Business Objective

The customer aimed to:

  • Reduce rapidly rising IT/OT operational costs without disrupting factory automation

  • Standardize, consolidate, and streamline applications across plants and global regions

  • Replace legacy, high-maintenance systems with modern low-code/no-code (LCNC) platforms

  • Improve system reliability and accelerate change management cycles

  • Strengthen cross-functional governance between Finance, Sourcing, and IT for spend control

Scope of Services

BXI Technologies delivered a global modernization and cost-optimization program:

Application Portfolio Assessment

  • End-to-end evaluation of IT and OT applications across all plants
  • Identification of redundant, obsolete, and underutilized systems

AI-Led Transformation Planning

  • AI-driven mapping of migration and upgrade paths
  • Consolidation strategy for low-code/no-code platforms

Application Modernization via SmartDev

  • Rationalization and modernization of legacy applications
  • Migration to LCNC platforms for faster, more cost-effective delivery

Finance & Sourcing Integration

  • Joint cost governance framework established
  • Contract optimization and license rationalization

Operational Streamlining

  • Removing application sprawl
  • Standardizing automation workflows across plants

Benefits

  • Significant reduction in IT/OT operational costs

  • Faster deployment cycles using LCNC platforms

  • Reduced dependency on traditional development and legacy vendors

  • Improved visibility and control over application sprawl and licensing

  • More reliable automation environment with fewer failures and downtime

  • Stronger partnership between IT, Finance, and Sourcing for continuous optimization

Impact

  • 25–35% reduction in total IT/OT application costs through consolidation

  • 40–50% faster rollout of new automation workflows via LCNC platforms

  • Up to 30% reduction in infrastructure footprint and recurring hosting costs

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