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Manufacturing

We help production industry clients excel in performance transformation, manufacturing strategy, manufacturing excellence, and capability building.

We specialize in transforming manufacturing operations through systems, infrastructure, and employee mindsets, and provide strategic guidance on a wide range of manufacturing issues such as network configuration, capital productivity, and make vs. buy decision-making.

How we work

Transforming manufacturing operations

Our approach to performance transformation addresses three main areas: the operating system; management infrastructure; and employee mindsets, capabilities, and behavior. We combine our knowledge of the world’s best operating systems with internationally recognized improvement programs, such as Lean, Six Sigma, and Theory of Constraints. We provide tailored solutions that allow clients to manage change dynamically—from the shop floor to the executive suite. In addition to helping implement our solutions, we mentor clients and build capabilities to sustain the changes.

Manufacturing strategy

We provide strategic advice to help clients design fast, flexible, and efficient manufacturing processes that connect supply chain to factory processes, production equipment, and production systems in a seamless, customer-centric network. Examples of areas of focus include:

  • Network configuration. We design plant networks to help companies improve their return on invested capital (ROIC) through reduced cost, increased efficiency, and enhanced growth opportunities.
  • Capital productivity. We advise clients on capital spending projects and help them to improve the return or yield from existing equipment through overall equipment effectiveness (OEE) and maintenance strategies.
  • Make or buy. We help companies decide whether to make or buy and then support the decision by aligning all their processes along the supply chain and building up the necessary internal capabilities.

Manufacturing excellence techniques

We develop best practice approaches and techniques to cover important core areas in manufacturing such as reliability, variability management, and quality, as well as on rapidly evolving current topics such as green manufacturing and IT-enabled operations.

Capability building

We develop programs for capability building in a multitude of formats including boot camps, model factories, lean academies, and proprietary tools. Our energy efficient and lean model factories enable us to demonstrate manufacturing techniques and approaches in a very tangible, practical way to clients spanning all sectors. These factories facilitate hands-on experience for clients on topics such as lean capability building, change agent leadership, and integrated performance transformation.

FEATURED EXPERTS

Katy George

Senior Partner, New Jersey

Christoph Schmitz

Senior Partner, Frankfurt

Featured capability

McKinsey model factories

Through our global network of capability centers, clients can “learn by doing” at model factories that simulate manufacturing, call center, and other workplace settings. The focus is on building capabilities—such as lean manufacturing, green operations, and quality control—and skills needed for transformational change.

RELATED INSIGHTS

Interview

The digital-manufacturing revolution: How it could unfold

– In this panel discussion with McKinsey’s Richard Kelly, three experts share their vision of how digitization may transform manufacturing.
Article

Digital manufacturing: The revolution will be virtualized

– Few manufacturers are responding to opportunities and threats presented by the digital revolution in a comprehensive, coordinated way. Learn how and why manufacturing industries require a digital transformation.
Article

Manufacturing’s next act

– Industry 4.0 is more than just a flashy catchphrase. A confluence of trends and technologies promises to reshape the way things are made.

Careers

Interested in a career in Operations?

We are currently looking for experienced professionals across all Operations disciplines.

Advanced Operations Group

Learn more about our group of Operations practitioners who bring deep functional and sector expertise from the industry.

Operations Excellence Program

Learn more about how our unique two-year training program, OEP, develops specialists in operations excellence.