Industry 4.0

Digital technologies are transforming industrial production processes from design and engineering to manufacturing. BCG helps harness the full potential of Industry 4.0: greater flexibility in processes, increased productivity and revenue, and higher-quality production.

Industry 4.0

BCG’s Industry 4.0 consulting embraces a holistic approach: we work across all production sites to ensure that everything from technology infrastructure to governance and competencies are integrated and aligned. Our focus is helping our clients build “factories of the future”—fully digital plants that deploy Industry 4.0 technologies and digital supply chain to achieve results that are sustainable, consistent, and scalable.

Innovation Center for Operations

Our Innovation Center for Operations is a global network of capabilities the includes state-of-the-art model factories and operations consulting. The center provides immersion, experimentation, and training on all topics related to Industry 4.0.

Mobile Labs

BCG can also bring the technologies to you—experience the industrial revolution 4.0 anywhere in the world with interactive workshops, thanks to our mobile labs.

  • Our Truck Line lab helps you experiment with implementing Industry 4.0 in discrete manufacturing, focusing on warehouse logistics and assembly efficiency.
  • Our Process Line lab simulates candy production, enabling you to visualize the benefits of quality control, material use, and maintenance in process industries. Both provide insight into more than 20 technology use cases, combine Industry 4.0 technologies and lean principles, and offer immersive training.

Proprietary Resources

As a BCG client, you gain access to a variety of our proprietary data collections:

  • Our Industry 4.0 Health Check, which assesses a plant’s digital maturity.
  • Benchmarks of key metrics in manufacturing and supply chains across major industries.
  • Our case study database, which contains reports of how Industry 4.0 technologies have been successfully implemented.
  • Our technology-vendor database, which details suppliers by industry to help you select the right one.

Meet Our Industry 4.0 Consulting Leaders

Managing Director & Senior Partner

Daniel Küpper

Managing Director & Senior Partner
Cologne

Managing Director & Senior Partner

Dustin Burke

Managing Director & Senior Partner
Chicago

Managing Director & Partner

Kristian Kuhlmann

Managing Director & Partner
Frankfurt

Partner & Director

Moundir Rachidi

Partner & Director
Paris

Unlocking Value Through Industry 4.0

benefits_industry4.0.png

By partnering with BCG, our clients achieve concrete and quantifiable gains. In an Industry 4.0 consulting engagement with us, these benefits can include:

  • Greater Efficiency. Gain 10% to 15% efficiency in the short term and 20% to 40% in the long term.
  • Greater Flexibility. Boost your changeover reduction by 20% to 60%.
  • Lower Cost. Cut the cost of raw materials by 2% to 5%.

BCG’s Featured Client Work in Industry 4.0

Using Analytics to Improve Overall Equipment Effectiveness

A global manufacturer of food and beverages turned to BCG to improve its overall equipment effectiveness (OEE). BCG used advanced analytics to deliver a 10-point lift in OEE.
Setting Up a Greenfield Factory

A consumer goods company was relocating its production. By working with BCG’s Innovation Center for Operations, the company set up an Industry 4.0 greenfield factory that slashed conversion costs by 13%, enhanced material flow, and optimized warehouse efficiency.

BCG's Latest Insights on Industry 4.0

Related Capabilities