We help reimagine manufacturing—whether single assets or global networks—into a digitally connected system where AI, automation, and data drive real-time decisions, execution, and continuous performance improvement.
Examples of our work
McKinsey partnered with a global technology corporation to transform their Mexico manufacturing facility into a Lighthouse Factory—one of the world's most advanced manufacturing sites—by designing over 100 digital initiatives, deploying nine advanced use cases, and integrating two cutting-edge Generative AI applications into daily operations.
To sustain the transformation, McKinsey established a central performance management engine, a manufacturing Center of Excellence, and a holistic capability-building program that upskilled 400+ frontline leaders, IT professionals, and managers. The result was an approximate 45% improvement in productivity and global recognition as a leader in AI-driven manufacturing.
Our Products
OptimusAI
Uses advanced analytics to optimize the efficiency and profitability of industrial processing plants, particularly in metals, mining, and chemicals, by enabling real-time, data-driven decision-making.
Manufacturing Excellence Accelerator
Helps manufacturers rapidly unlock productivity, efficiency, and capability-building at scale by embedding proven operational excellence practices into everyday operations.
Energy System Optimization
Uses digital-twin to model and simulate complex industrial utility networks (such as steam and power) to identify the most cost-effective, carbon-efficient operational setpoints and capital investment decisions.
Frontline Digitization
Offers rapidly customizable IoT applications designed to digitize shop-floor workflows and empower frontline operators with real-time performance tracking.
Capability Building
McKinsey Academy
Delivers best in class capability building programs that leverage customizable, state of the art assets designed to enable learning by doing, and helping operations leaders develop the skills, mindsets and behaviors required to drive value and sustain impact.
Innovation & Learning Centers
Offers immersive, hands-on environments to teams across the globe where leaders experience the latest tech, build critical capabilities, and accelerate transformation, turning strategy into impact through interactive simulations and practical application.
HOW WE HELP CLIENTS
Industry 4.0
Deliver and scale digital transformations that connect and automate the shop floor.
Lean+
Implement foundational Lean together with our digital toolkit to accelerate impact and make transformation stick.
CO2 optimization
Optimize emissions across the manufacturing value chain.
Frontline workforce excellence
Execute strategies that drive workforce attraction, retention, engagement, and performance.
Featured Insights
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Transforming factories: The power of continuous, connected insights
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By quickly connecting insights to execution, companies can accelerate their factories’ path toward manufacturing excellence...
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From pilots to performance: How COOs can scale AI in manufacturing
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A new survey of manufacturing COOs shows high hopes for scaling AI—and high budgets. But some companies may be underinvesting...
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Lighthouse lessons: Four mindsets to make digital transformation stick
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Adapting to rapidly evolving technology means investing in people who drive change on the ground.