Reinventing Manufacturing Through Frontline Enablement

Reinventing manufacturing operations through intelligent frontline enablement

A joint manufacturing transformation story by HCLTech and Zebra Technologies

5 min read

Overview

The manufacturing industry stands at a pivotal crossroads. Economic uncertainty, pressure on global supply chains and fast-paced technological innovation are forcing manufacturers to rethink their operations from the ground up. Efficiency, visibility and speed are no longer advantages — they are minimum requirements.

To keep up, manufacturers are adopting intelligent operations — but technology alone isn’t enough. True value depends on how seamlessly new tools are integrated into frontline workflows and day-to-day decision-making.

This was precisely the challenge for the world’s leading food and beverage manufacturer as they set out to transform their manufacturing operations and frontline workforce.

The Challenge

Bridging the real gap

Although the organization operated on a global scale with mature systems, they faced a persistent disconnect. Their enterprise platforms were advancing but frontline execution was still hindered by manual steps and a patchwork of outdated tools.

Key challenges included:

Manual, paper-based workflows slowing production processes and increasing the risk of errors
Limited real-time visibility into inventory levels and production status, impacting timely decision-making
Fragmented communication across shifts, teams, and facilities, leading to coordination gaps
Inconsistent and outdated tools across sites, reducing standardization and efficiency
Complex device management requirements, including security, compliance, and lifecycle oversight at scale

The leadership quickly saw that small tweaks wouldn’t cut it. They needed a flexible, scalable approach that would put the right technology directly into the hands of frontline teams.

The Objective

Aligning technology, integration and execution

To achieve this vision, the organization chose Zebra Technologies and HCLTech and as their global systems integrator to spearhead the frontline and manufacturing modernization journey whose rugged, purpose-built devices are designed for the realities of industrial environments.

Through this collaboration, HCLTech and Zebra delivered a truly integrated solution — blending industrial-strength hardware with end-to-end deployment, management and lifecycle expertise.

The Solution

Technology enablement built for manufacturing reality

The rollout strategy centered on standardized but adaptable device configurations, tailored to the unique demands of manufacturing and distribution.

Deployed technologies included:

Mobile computers: Zebra MC9400/MC9450, TC73/TC78, TC53/TC58
Industrial printers: Zebra ZT400 Series
Barcode scanners and tablets: Delivering real-time data capture and inventory control

Hundreds of devices launched across manufacturing plants and distribution centers in EMEA and LATAM ensured a consistent digital backbone — all while accommodating each site’s specific workflows.

Clear objectives shaped the transformation:

Digitize manual workflows
Cut out the paper trail with automated scanning and real-time data entry.
Increase workforce productivity
Put mobile tools in the hands of frontline teams to streamline tasks and reduce bottlenecks.
Improve inventory accuracy and traceability
Leverage barcode and RFID devices to support precise tracking.
Strengthen security and compliance
Centrally manage, track and secure endpoints with Microsoft Endpoint Manager, anchored by HCLTech’s Unified Endpoint Management (UEM) strategy.

Every objective was targeted to turn technology adoption into real, measurable business value.

The Impact

Transformation where it matters most

With the HCLTech–Zebra solution up and running, the organization saw operational improvements where they counted most.

Operational efficiency improved at the point of work
Rugged Zebra devices made frontline execution faster, more consistent and less prone to errors or downtime.
Real-time visibility enabled smarter decisions
Plant leaders could instantly view inventory, metrics and production data — shifting from reactive to proactive, data-driven decisions.
Frontline teams became more enabled
Features like Push-to-Talk and digital scheduling made communication clear and direct. Collaboration improved across shifts, boosting coordination and accountability.
Scalability was embedded from day one
Thanks to HCLTech’s Device-as-a-Service (DaaS) model, scaling deployments or refreshing devices was frictionless — supporting current requirements and long-term growth.

Strategic value: From device deployment to connected manufacturing

Beyond operational gains, the collaboration set the stage for continuous, global improvement. HCLTech and Zebra worked hand in hand to build a secure, standardized manufacturing environment ready to scale.

The manufacturing leader now benefits from:

A repeatable model for frontline digitization in any region
Robust governance, security and compliance through centralized management
Improved sustainability by managing device lifecycles for maximum value

What started as a device rollout became the foundation for intelligent, connected manufacturing.

Conclusion

A blueprint for the future of manufacturing

This story shows how HCLTech and Zebra Technologies — through strong partnership and strategic alignment — are helping manufacturers bridge the gap between digital vision and everyday execution.

By modernizing how frontline work gets done, securely and at scale, we enable organizations to realize sustainable gains in efficiency, visibility and resilience.