Lean and Manufacturing Challenge


The factory of the future is powered by digitization and fuels sustainability. We help our manufacturing clients navigate a shifting landscape of supply chains, technologies, and talent to make the products the world demands in the ways the planet needs.

New technologies have upended industrial production. As a result, manufacturers are turning toward factories of the future. But they must address critical questions about just which manufacturing technologies, structures, and processes to embrace, what they will manufacture, and where and how they will manufacture it. Our manufacturing consulting experts help clients make the decisions that shape countless conditions: environmental footprint and sustainability, cost profile, exposure to risks, workforce requirements, customer targeting, and ultimate profitability.

How BCG Works With Manufacturing Clients

Our manufacturing consulting experts coach and enable our clients on strategic and operational initiatives, helping them innovate and digitize their shop floors—where value is created. Our experts, backed by advanced data and analytics and a dedicated engineering team, work with clients to cut through complexity and achieve successful manufacturing transformations.

Our manufacturing consulting focuses our clients on three essential guiding questions:

What Will You Manufacture?

Your product, product lines, and underlying components establish your manufacturing strategy. This includes what you make in-house versus buy through a supplier, as well as your supply chain and how you optimize it along with your manufacturing operations. BCG brings expertise in manufacturing strategy and organization, risk management, sustainable operations, and make-or-buy decisions.

Where Will You Manufacture?

You must decide not only in which locations your plants and distribution centers sit, but also how they’re optimized for such particulars as regulations, logistics, taxes, and duties. Our manufacturing consulting experts help clients make the best decisions using our advanced production network optimization tools like SNOW AI and the Global Manufacturing Cost-Competitiveness Index.

How Will You Manufacture?

BCG helps evaluate your supply chain by viewing your global manufacturing operations through an integrated lens—ensuring everything from your lean manufacturing practices to your use of advanced robotics performs at a world-class level. We help you envision and build factories of the future that incorporate Industry 4.0 technologies, maintenance and production engineering strategies, logistics capabilities, lean production systems, and quality processes.

Our Approach to Manufacturing

BCG’s manufacturing consulting clients enjoy access to a broad range of resources, including our Innovation Center for Operations. The following are among the tools and offerings we deliver.





Examples of Our Client Work in Manufacturing

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BCG Ranks as a Worldwide Leader in Operations Improvement Consulting

BCG was named a leader in the IDC MarketScape: Worldwide Operations Improvement Consulting Services 2023–2024 Vendor Assessment due to our focus on fast, measurable impact through execution and more.

Our AI-Powered Manufacturing Solutions


Supply Chain AI

Supply Chain AI takes a holistic approach to transforming a company’s supply chain, from strategy and design through integrated planning and optimized execution. Backed by a unique set of AI solutions from BCG X, we enhance seven key supply chain capabilities while developing the plans, processes, skills, and culture that fuel and accelerate transformation.

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Powered by cutting-edge machine learning and optimization models, BCG X's proprietary advanced analytics solution solves end-to-end supply chain optimization problems easier, faster, and more cost-effectively.

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MFG AI’s integrated offering for AI-powered manufacturing transformations brings together BCG’s operations know-how and advanced analytics capabilities to unlock value at scale on the shop floor, enabling a 10% to 25% productivity improvement.

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BCG-WEF Project: AI-Powered Industrial Operations

Manufacturers need to optimize for increased productivity, improved sustainability, greater resilience, and a stronger workforce. How can they harness the latest technologies to realize these goals?

Our Latest Insights in Manufacturing


Building the Factory of the Future Today​

BCG’s Daniel Kuepper explains how manufacturers can strategically approach cost management to bring about the factory of the future while reducing costs in the present.

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