Tag: Manufacturing

Customer

A global leader in energy flow measurement and optimization operating across 130+ countries undertook an energy industry digital transformation to modernize its technology landscape. The organization manages mission-critical systems for measuring and optimizing the flow of natural gas, electricity, and water at global scale. However, growing device complexity and operational demands required a more resilient, intelligent, and scalable digital foundation to support Industry 4.0 initiatives and real-time decision-making.

Business Objective

The client aimed to:

  • Improve product quality and significantly reduce equipment breakdowns

  • Modernize applications and infrastructure to support Industry 4.0 initiatives

  • Build real-time operational intelligence for proactive maintenance and performance monitoring

  • Enhance global support coverage with 24/7 operational reliability

  • Reduce IT and operational costs through automation and tool consolidation

Together, these objectives defined a transformation roadmap focused on resilience, intelligence, and scalable global operations.

Scope of Services

Quality Engineering & Testing

  • Automated testing and CMS validation

  • Capacity, load, and performance testing

  • Device connectivity and responsiveness testing

  • Enterprise quality assurance for major product releases

Data & Analytics Support

  • Real-time event monitoring and optimization

  • Data engineering and analytics enablement

  • Actionable insights to improve equipment maintenance and reliability

Application & Infrastructure Modernization

  • Legacy-to-cloud application modernization

  • SAP S/4HANA transformation and SAP mobility for field workers

  • Migration to low-code/no-code platforms

  • Rationalization of tools, applications, and legacy systems

Infrastructure & Operations

  • 24/7 Service Desk (L1 & L2)

  • Server, storage, and data center management

  • Cloud operations (IaaS), VDI, and middleware support

  • Database administration and end-user computing

  • Managed network services, disaster recovery, and cybersecurity operations

This energy industry digital transformation program established a modern foundation for real-time monitoring, predictive maintenance, and scalable global operations.

Benefits

As a result of the transformation, the client realized:

  • Improved product quality and device reliability across global operations

  • Proactive maintenance enabled by real-time operational intelligence

  • Faster issue detection and resolution through automated diagnostics

  • More resilient and responsive connected device ecosystems

  • Streamlined global operations supported by a unified delivery and support model

  • Greater agility and scalability of IT and operational environments

  • Stronger cybersecurity posture and improved business continuity

Impact

  • 51% cost optimization through automation, tool consolidation, and modernization

  • 33% improvement in operational efficiency driven by testing-led optimization

  • Up to 80% reduction in equipment breakdowns

  • Significant reduction in OEM MTTR (Mean Time to Repair)

  • 24/7 operational support coverage across 130+ countries

  • End-to-end visibility enabled across global operational infrastructure

 

Customer

A global manufacturing enterprise operating across multiple geographies initiated an AI-driven cybersecurity modernization program to protect its production systems and global supply chain. As digital adoption increased across plants, frequent cyber incidents began disrupting operations, increasing costs, and impacting productivity. Therefore, the organization required a modern, intelligent security foundation capable of proactively identifying threats and safeguarding business continuity at scale.

Business Objective

The organization set out to:

  • Reduce escalating cybersecurity-related costs

  • Strengthen threat detection and incident response capabilities

  • Ensure uninterrupted production and supply chain operations

  • Shift from reactive security measures to proactive cyber risk management

  • Improve profit margins through greater operational resilience

Together, these objectives defined a roadmap for cybersecurity modernization aligned with business continuity and growth.

Scope of Services

BXI Technologies partnered with the client to modernize its cybersecurity environment end to end. The engagement focused on replacing fragmented, outdated security tools with an AI-driven, automated, and globally scalable security model.

The scope included:

  • Modernization of the cybersecurity architecture across IT and OT environments

  • Deployment of AI-driven, real-time threat detection and monitoring

  • Automation of incident response and resolution workflows

  • Predictive analytics for vulnerability identification and risk forecasting

  • Cloud-based managed security services to support global operations

  • Unified security operations across business units and geographies

This AI-driven cybersecurity modernization initiative established a unified, automated security operations model across all business units and geographies.

Benefits

As a result of the transformation, the organization realized:

  • Improved operational continuity across manufacturing and supply chain systems

  • Faster and more consistent threat detection and response

  • Reduced reliance on manual security interventions

  • Greater resilience against production disruptions caused by cyber incidents

  • Improved scalability and readiness to support global operations

  • A future-ready cybersecurity posture aligned with regulatory and compliance needs

  • Stronger foundation for safe digital transformation initiatives

Impact

  • 40% reduction in system downtime through automated incident response

  • 25% decrease in annual cybersecurity costs via tool consolidation and automation

  • Significant reduction in incident frequency through predictive risk identification

  • 15% improvement in profit margins due to fewer disruptions and faster recovery

  • Global, 24/7 security coverage enabled through managed security services

 

Customer

Supply Chain Modernization for a Multinational Automotive Manufacturer

Business Objective

The customer aimed to:

  • Stabilize supply chain operations impacted by volatility and supplier inconsistency

  • Improve real-time visibility across procurement, warehousing, and logistics

  • Enable predictive analytics to anticipate delays and disruptions

  • Reduce manual decision-making through AI-driven automation

  • Strengthen supplier evaluation and risk-scoring frameworks

  • Accelerate procurement and logistics execution with higher accuracy

Scope of Services

BXI Technologies delivered an end-to-end AI-enabled supply chain modernization program:

Agentic AI Deployment

  • AI agents for supplier conversations, clarifications, and exception handling
  • Automation of routine supply chain decisions

Predictive Intelligence

  • Models to forecast demand fluctuations, delays, and disruption risks
  • Predictive alerts for early intervention

Unified Visibility Layer

  • Real-time dashboards integrating procurement, logistics, warehouse, and supplier data
  • Cross-site operational visibility to reduce blind spots

Supplier Performance & Risk Management

  • AI-driven supplier risk scoring and performance evaluation
  • Structured insights for improved sourcing decisions

Operational Optimization

  • Faster, more accurate procurement actions
  • Automated issue detection and mitigation workflows

Benefits

  • Real-time visibility across procurement, logistics, and supplier operations

  • Predictive analytics enabling early detection of operational risks

  • Centralized dashboards reducing fragmentation across sites

  • Automated alerts replacing manual monitoring

  • Improved supplier evaluation with consistent AI-driven scoring

  • Faster decision-making powered by intelligent recommendations

  • Proactive disruption mitigation, minimizing operational impact

  • Reduced friction across procurement and logistics teams

  • Stronger coordination between suppliers, warehouses, and logistics partners

Impact

  • 28% reduction in supply chain delays through predictive alerts and early interventions

  • 35% improvement in procurement accuracy with AI-driven recommendations

  • 22% reduction in logistics costs through optimized routing and reduced last-minute changes

  • 40% faster response time to disruptions enabled by real-time visibility

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

Customer

Intelligent Sourcing & Risk Hedging for a Leading Power & Industrial Equipment Producer
A global leader in transformers, heavy electrical systems, and industrial power equipment, heavily dependent on CRGO steel and other volatile raw materials. With market fluctuations accelerating and competitors adopting advanced forecasting, the customer needed a smarter, data-driven procurement approach. The goal was to build sourcing intelligence that could stabilize planning, reduce volatility exposure, and strengthen resilience across the production lifecycle.

Business Objective

The customer sought to:

  • Stabilize procurement planning despite extreme CRGO and raw-material volatility

  • Improve forecast accuracy for critical materials essential to production continuity

  • Strengthen sourcing decisions with deeper, data-backed insights

  • Reduce exposure to high-risk or unreliable suppliers

  • Improve negotiation leverage during volatile market cycles

  • Build proactive early-warning capabilities for shortages, spikes, and disruptions

Scope of Services

BXI Technologies addressed major procurement challenges, including:

  • Extreme price fluctuations in CRGO and other metals

  • Competitors adopting AI-driven forecasting, increasing market pressure

  • Manual procurement planning leading to delays, errors, and reactive decision-making

  • Limited supplier visibility and high-risk exposure

  • Lack of consolidated insight into market trends, risks, and alternatives

Our work included:

  • Implementing advanced forecasting models for raw-material trends

  • Integrating real-time market intelligence and volatility indicators

  • Building supplier risk scoring and sourcing alternatives

  • Automating alerts for price spikes, shortages, and disruption signals

  • Creating a unified procurement intelligence dashboard

Benefits

The customer achieved:

  • Faster procurement decisions backed by reliable data

  • Clear visibility into raw-material behaviors and market patterns

  • Improved negotiation leverage through stable forecasts

  • More predictable and stable production planning

Impact

  • 20–30% better forecast accuracy

  • 15–25% procurement cost savings

  • 30–40% fewer firefighting events (shortages/spikes)

  • Up to 20% reduced reliance on high-risk suppliers

Customer

Digital Twin–Enabled Scale-Up Acceleration for a Global Industrial Manufacturer
A multinational industrial manufacturing company operating complex production lines across multiple regions. The organization faced recurring delays, late-phase quality failures, and unpredictable performance during scale-up of new or modified production lines. To avoid costly capex overruns and ensure smoother commissioning, the company needed a digital-twin-driven approach that could validate behavior, simulate risks, and align engineering and operations before physical deployment.

Business Objective

The customer aimed to:

  • Minimize execution and quality risks during production scale-up

  • Validate production behavior virtually before real-world deployment

  • Avoid costly capital expenditure overruns caused by late-stage failures

  • Improve predictability of throughput, load, and quality metrics

  • Strengthen collaboration between engineering, operations, and process teams

  • Accelerate production readiness with higher confidence

Scope of Services

BXI Technologies delivered an end-to-end digital-twin modernization program, which included:

  • Production line scale-up planning and quality-risk assessment

  • Integration of a full digital twin environment mirroring physical production systems

  • Operational risk modeling and scenario simulation for “what-if” analysis

  • Validation of throughput, load, and equipment behavior prior to deployment

  • Cross-functional alignment between engineering and operations to ensure shared visibility and decision-making

Benefits

  • Early detection of quality risks before physical trials

  • Stronger collaboration between engineering and operations teams

  • Reduction in rework cycles and scale-up delays

  • Higher confidence in capex decisions backed by virtual validation

  • Improved readiness of production teams prior to real-world execution

Impact

  • 35–45% reduction in scale-up execution risk

  • 30–40% fewer quality defects during initial production runs

  • 25–35% faster production ramp-up time

Customer

Consumer Durables IT Efficiency & Digital Enablement is the focus for a well-known Consumer Goods and Consumer Durables company specializing in Home Appliances.

Business Objective

The company set three strategic priorities to support its next phase of growth:

  • Improve operational efficiency across IT and business processes

  • Expand value-added products and services to grow share-of-wallet

  • Increase customer penetration through better digital experiences

The leadership identified IT modernization as a core lever to enable scale, faster time-to-market, and better support for field operations.

Scope of Services

The Consumer Durables company, operating across the U.S., wanted to improve IT efficiency across its portfolio while simultaneously addressing the needs of field staff for a better digital experience.

A significant merger with a neighboring regional Consumer Durables company, combined with market expansion into new products and services, created increased demand for IT services.

To support this growth, the Enterprise Architecture (EA) team began exploring a platform-based approach to deliver core technical capabilities that could solve current challenges and remain flexible for future needs.

Benefits

  • Centralized and trusted data management enabled better insight generation

  • Standardized governance and validation processes improved control and consistency

Impact

  • 45% cost efficiency achieved through trusted data management, improved governance, and digital enablement across the organization

  • 30% productivity gain driven by early digital engagement for field staff, reducing friction in daily workflows

  • Digitized workflows improved user experience across digital tools

  • Streamlined feedback mechanisms enabled stronger field engagement and continuous improvement

 

Customer

A clothing division needed to work with channel partners to grow digital commerce revenue.

Business Objective

  • Overcoming E-Commerce Integration Challenges

  • Transforming Multichannel Distribution for Unified Commerce Success.

  • A sought to improve its channel partners’ digital commerce capabilities. but was unsure which investments would result in maximum revenue growth.

Scope of Services

E-commerce businesses and retailers expanding their multichannel distribution capabilities will need to integrate multiple applications and systems both within and outside the company to strive toward unified commerce capabilities.

In their efforts to build an integrated e-commerce ecosystem often face multiple challenges such as:

  • Lack of end-to-end process visibility and orchestration

  • Inefficient integration capabilities to meet the business needs

  • Constrained ability to make effective decisions due to siloed data

  • Lack of overarching governance and integrations control due to the consumerization of e-commerce applications

Due to the variety of applications needed to serve the needs of high-volume, high-velocity and high-variability e-commerce activities, many organizations struggle to effectively integrate their business processes.

Benefits

  • We could assess the need to invest in an integration platform by evaluating the impact critical challenges hampering e-commerce growth they have on the business.

  • Help them select the right-fit integration platform provider by assessing vendor capabilities across three dimensions: business, technology and ecosystem support.

  • Accomplished e-commerce performance objectives by creating a robust integration plan with the platform provider.

Impact

  • Roughly has seen a 30% growth in the share of total sales through digital commerce from 2019 to 2021.

  • Most channel partners that we have strategically partnered with on digital commerce efforts are now growing faster and becoming more profitable for us, so our growing digital commerce business serves as a proxy for sustainable, profitable growth.

Customer

A leading e-commerce giant in the European market, operating 20+ consumer brands across six regions and over 150 countries. The business manages a large global portfolio and must coordinate marketing execution across markets with varying maturity, channels, and customer expectations. Their scale demands highly agile marketing operations, centralized intelligence, and personalization at speed.

Business Objective

The customer wanted to:

  • Transform global marketing operations into an agile, scalable operating model

  • Enable personalized, consumer-centric marketing at global scale

  • Increase customer penetration across multiple brands and regions

  • Replace decentralized, manual processes with unified systems and coordinated execution

  • Improve visibility and decision-making across regions and business units

  • Identify and size value opportunities to build adoption and leadership alignment

  • Establish a multi-year digital and MarTech transformation roadmap

Scope of Services

BXI partnered with the customer to execute a global marketing transformation program, including:

Strategic Marketing Transformation

  • Defined the vision & personalization ambition across 20+ brands

  • Created top-down opportunity sizing to secure leadership commitment

  • Established a multi-year value capture plan, linked to sprint-level execution

Operating Model Redesign

  • Designed and launched four cross-functional agile pods

    • personalized campaigns

    • channel operations

    • data & insights

    • experimentation

  • Tested personalization use cases in-market with real customers

Data & Measurement Enablement

  • Built a customer marketing data testing environment

  • Enabled pod teams to generate insights on-demand

  • Implemented measurement framework to track impact of use cases

Transformation Roadmap

  • Defined a 2.5-year MarTech transformation roadmap with 80+ initiatives

  • Prioritized platform development, data integration, and marketing process scale-out

Benefits

  • A unified vision for personalized customer marketing at enterprise scale

  • Clear opportunity sizing to align leadership and accelerate adoption

  • Agile pods established to test and scale personalization in real markets

  • Multi-year value capture plan aligned to sprint execution

  • On-demand customer data and insights enabling rapid experimentation

  • A structured testing environment to measure impact of use cases

  • Strong cross-functional alignment across brands, regions, and leadership

Impact

  • ~$250 million projected cost savings from process and platform efficiencies

  • ~15% projected revenue growth via consumer-centric marketing approach

  • 80+ initiatives included in a 2.5-year MarTech roadmap

  • 100% leadership buy-in for a unified digital transformation vision

Customer

An India headquartered multinational steel manufacturing giant and has operations in 26 countries and have a commercial presence in over 50 countries with employees across five continents. It is Europe’s 2nd largest steel producer.

Business Objective

  • Provide a scalable skilled resource pool
  • Innovation delivery model taking advantage of Automation, Self-Healing, and Auto healing.
  • Support Data & Analytics
  • Tool Rationalization
  • Infrastructure Modernization

Scope of Services

  • Multilingual Technology WPS
  • Application Service Desk – 24×7 Service desk support for 300+ applications delivered from 4 client locations in India.
  • On Premise Support in 3 client manufacturing locations across India
  • Dedicated Operations Management Centre at Mumbai office
  • Delivery Locations: 4
  • Volumetric Data: 29,000 tickets/ monthly; 40,000+ Users; 4 Contact mediums
  • English + Indian Languages support

Benefits

  • Dedicated Regional Service Delivery Model
  • Business aligned Smart Ops to focus on Self Service, Self-healing, and auto healing
  • Unified Operation Centre that Service Desk L1 & L1.5 and Tool Consolidation
  • SmartOps rollout for Monitor, Detect, and Resolve proactive events across tracks,
  • Digital Services Hub – Single Point of Accountability
  • Process Efficiency – through SOPs and improved FCR

Impact

  • 95% Reduction in time for gate pass
  • 20% Increase in First Call Resolution
  • Consolidation of two different Service Desks resulting in a Centralized service desk – giving the client a single source of accountability