Your journey to full potential begins with a detailed, clear-eyed assessment of where you stand today. Only Bain offers a Manufacturing Full Potential Diagnostic that provides a standardized approach and proprietary benchmarks that give you a qualitative and quantitative assessment of your starting point.

Available as either a rapid (2-4 days) or comprehensive (4-6 weeks) assessment, our diagnostic assesses four critical facets of manufacturing: supply chain, footprint design, plant performance, and digital/Industry 4.0.

See where you’re strong, where you lag, and what the savings potential can be when you improve specific elements of your performance and capability. Our benchmarking database of 250+ plants across a wide variety of industries captures today’s most relevant KPIs, allowing you to visualize your current state, spot areas of opportunity and prioritize the actions that will vault you ahead of your competitors.

The Internet of Things (IoT) is ushering in a new era of predictive maintenance, self-optimizing production and a host of other benefits. Companies are harnessing the power of their data in new ways, including the use of AI and machine learning. Workforce training is of paramount importance as manufacturers build the skills they need to exploit new technologies. And virtual and augmented reality and “cobots” are changing how work gets done.

More than half of all companies have taken some steps to incorporate these new digital/Industry 4.0 technologies into their operations, but only 5% have fully tapped their potential. We can help you embed these new technologies into every facet of your operations and explore the possibilities for launching new, disruptive business models based on digital capabilities. We bring broad expertise to Industry 4.0, including our unique partnership with Bosch. 

Companies that have taken leadership positions in digital operations have achieved impressive results, including a 30% boost to both revenue and customer loyalty, and a 30% reduction in process costs.

Achieve game-changing results with our Lean Full Potential Transformation, a cross-functional approach that accelerates the financial, operational, and strategic trajectory of your business.

We take a “four-wall” approach that will diagnose, design, deliver and orchestrate your transformation. We apply digital technologies across the full breadth of our approach, to reduce complexity and enhance productivity. And we help you maintain focus, change behaviors, mitigate risks, and assign the right people to the right roles to inspire and maintain change. 

We’ll show you how (and why) Lean Transformation needs to be line-led, and we’ll help your teams develop the Agile development skills that get results quickly. 

Our approach gets results fast, encourages buy-in, boosts accountability and creates a culture committed to driving down costs. 

A well-designed and effectively executed manufacturing strategy accelerates revenue growth, boosts customer satisfaction and advocacy, unlocks savings and cash flow, and minimizes risks while enhancing reliability. But most manufactures settle for incremental improvements rather than bold reinvention.

Leading manufacturers go a different way. They:

• Define the strategy and make key decisions early
• Foster continuous improvement through lean principles and an empowered organization
• Address structural and systems issues aggressively
• And, use benchmarking, price- and cost-experience curves to gain an outside-in perspective on performance enhancement.

We can help you take an unconstrained view of what’s possible.  Our approach is highly customized to your specific competitive situation, and augmented by a range of best-in-class tools. Some companies will target a complete transformation, while others will pursue discrete initiatives to achieve excellence in select operational areas.

As technology, demographics, government regulations and policies, and a host of other forces alter the manufacturing landscape, and as manufacturers find that they have exhausted the gains that traditional best practices provide, the time is right to take a more ambitious approach to strategy, one that reinvents how you operate—and reignites your growth.