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January 2018
Contents
Foreword 3
Executive summary 4
Endnotes 30
Acknowledgements 31
Within the System Initiative’s framework, the Technology and Innovation for
the Future of Production project, developed in collaboration with McKinsey
& Company, is exploring how industrial companies can take technology
adoption in production from proof of concept to industrial scale. The project
is also examining how governments and civil society can best support the
development of a favourable ecosystem for adopting and diffusing technology
Enno de Boer across industry sectors.
Partner, McKinsey &
Company, USA This White Paper summarizes new findings, conclusions and recommendations
for governments and businesses, drawn from desk research and extensive
consultations from May to November 2017. The goal is to inform the design of
future strategies for the adoption and diffusion of Fourth Industrial Revolution
technologies at scale through strengthened public-private collaboration.
With the advent of the Fourth Industrial Revolution, To maximize the potential gains in productivity brought by
countries and companies have an opportunity to counter technology, companies must move from pilots to adopting
and potentially reverse the slowdown in productivity technology at scale, across multiple production facilities
by diffusing and adopting technology at scale. In fast- and through relevant value chains. They also must take
evolving and converging technologies for production, their suppliers (often SMEs) and customers with them to
accelerated growth and maturity are occurring like never be able to innovate and transform their businesses models.
before. The latest developments of the internet of things Governments need to develop the right set of policies and
(IoT) allow for connecting and tracking asset performance protocols to facilitate the dissemination and adoption of
in real time, as well as for integrating production and technology at the national level. Moreover, international
consumption processes. Artificial intelligence, which since cooperation and public-private partnerships must help to
2015 has achieved image and speech recognition at the elevate productivity so that it benefits the global economy.
level of the human brain, can process large amounts of Through its work in 2017, the Technology and Innovation
data that factories collect to increase efficiencies and for the Future of Production project has generated new
inform accurate decision-making. Advanced robots insights and actionable recommendations for companies
and computers can perform a range of routine physical and governments to accelerate the adoption and diffusion
activities and increasingly accomplish activities requiring of technology at scale.
cognitive capabilities, such as tacit judgements or sensing
emotions. According to the McKinsey Global Institute, more The findings, conclusions and recommendations in this
than 60% of all manufacturing activities can be automated White Paper are based on structured interviews with
with current automation technology.1,2 select leaders and experts from the public and private
sectors, academia and civil society. In addition, the World
These changes are driving the world towards a future of Economic Forum leveraged insights from McKinsey &
production characterized by autonomous, self-organizing Company’s technological network of partners; its annual
factories and integrated or hyperconnected production Digital Manufacturing Global Expert Survey, with responses
systems. Manufacturing companies, suppliers and from over 400 experts; and the latest IoT Pulse Survey,
customers will ultimately be connected on a common IoT with responses from over 300 business leaders. The
platform. Technology will empower the factory worker and insights and recommendations in this White Paper will be
plant manager, with a third of tasks almost fully automated, presented and discussed at the World Economic Forum
thus shifting the focus from execution of repetitive and Annual Meeting 2018 in Davos-Klosters, Switzerland, and
inefficient tasks to innovation. Technologies of the Fourth used to define key public-private collaborative interventions
Industrial Revolution will generate inclusive growth and needed to accelerate technology diffusion across
bring benefits beyond the factory’s four walls. They will industries and geographies.
potentially deliver up to $3.7 trillion in value3 for the global
economy, offering new products and services to society
and supporting the environment by optimizing resource
consumption.
Despite the recent slowdown in global growth, production 1. Connectivity: Rapidly expanding through the internet
continues to be a critical driver of the economy in of things (IoT), connectivity has reached global scale,
developed and developing countries. It is the main source with 8.4 billion devices connected.7 As of today, only
of investment in research, development and innovation 15% of assets are connected in production, but that is
(R&D&I), with manufacturing companies responsible for changing rapidly. The technology industry is working
more than 85% of the R&D carried out by the private sector on more than 700 IoT platforms8 for industrial use, and
in Germany, Japan and South Korea.5 major technology companies are investing heavily in
hyperscalable IoT platforms.
Technology and innovation have been and will remain
central to how production evolves and is transformed. Over 2. Intelligence: Artificial intelligence, advances in
the past 20 years, worker productivity across industries computing power and the availability of big data are
in the United States increased by 47%,6 driven primarily allowing machine learning algorithms to excel. In fact,
by technology adoption and innovation. Society is at the speech and image recognition have already reached
juncture of the increasing convergence of production and the accuracy of the human brain. The full potential of
consumption, which is mainly driven by new business artificial intelligence in production is however, yet to be
models enabled by transformations in technology. In the realized; only a small fraction of data is currently used
context of the Fourth Industrial Revolution, production is at for decision-making. For example, on an oil rig, the
the cusp of a paradigm shift driven by three technological research found that while 100% of data was captured,
megatrends that have reached unprecedented pace and only 0.5% was used to make decisions.
breadth (Figure 1), even as their full-scale adoption and
benefits in production is yet to be realized. 3. Flexible automation: Automation technology can
currently automate 60% of all manufacturing tasks.9
However, the current level of penetration of industrial
robots is still comparatively low, even in leading
adopters such as South Korea, where only 530 robots
per 10,000 production workers are deployed.10a
Connectivity
Creates links between
discrete network nodes,
increasing visibility
Flexible
Intelligence automation
Automates event Incorporates
recognition and response
translation for mechanisms,
decision-making automation and
remote movement
1 2 3 4
Autonomous Seamless connection Connection of supply New value-added
manufacturing of value chains chains to supplier services and business
ecosystem model innovations
“We need to fully leverage digital and technological advancements to be able to predict and capture consumer
demand, and connect it seamlessly through production operations and materials sourcing. This will require
reskilling and empowering our workforce to harness the new forces of technology. When doing this responsibly,
we create value across the supply chain using resources sustainably and helping our surrounding communities
to prosper.”
Mohamed Samir, President, India, Middle East and Africa, Procter & Gamble, United Arab Emirates
6 The Next Economic Growth Engine
2. Escaping from pilot purgatory in the
Fourth Industrial Revolution
Based on the research, technologies of the Fourth their production processes; 41% are still piloting solutions
Industrial Revolution are showing positive returns and at a single site or business unit, and the remaining 30%
new opportunities for growth. Nevertheless, the adoption have yet to or are about to start the journey (Figure 3).11
of technology in production still remains slow across More than 400 global digital manufacturing experts have
industries and regions: only 29% of industrial companies confirmed the slow pace of adoption, which is true across
have started to roll out new technological solutions across industries and regions.12
Figure 3
Figure 3: Technology adoption at scale is lagging
Most companies are struggling to successfully transition “We are in the middle of a consumer-driven growth
from pilots to large-scale, impactful deployments. revolution. Business leaders who deliver a customized
The principal reasons are the difficulty of aligning the experience at scale will win the day. Rising innovations
organization around the potential value and return on like AI, machine learning, blockchain and industrial IoT
investment, the uncertainty of digital’s value to their help make this bold vision into compelling reality.”
performance (especially in the short term), the cost
of resources needed to implement new solutions and Bill McDermott, Chief Executive Officer, SAP, Germany
the investments required to take them to scale. Figure
4 provides more details on the challenges hindering
companies from adopting technology at scale.
Too manyplatforms
Numerous use cases to prove out
to test 27 32
Figure 5
Figure 5: Difficulties in transitioning to large impact at scale
% respondents
Time spent piloting
56
28
15
% respondents
IoT platforms piloted
63
31
7
54
44
Augmented reality-guided
Optimize end-to-end
42 Predictive supplier network -
analytics including rdering,
Onsite 3-D workflow in rationalization,
assembly operations
8 printed tooling parallel with pricing - from a
Smart work 25
instruction assembly standard central platform
37
Digital analytics creation portal process 27
to optimize shop- Remote 46
Real-time IoT-based
Rapid 19 production
production floor processes 49 Digital machine
and visual optimization 40 health
through 3-D through real-
manufactu- performance Smart asset Predict performance Remote field
time analytics 12 network
end-to-end machinery boards to forecast
performance management
ring management Robotic CAE
value chain failures from simulation to maintenance optimization
component 26 In-line parts using sensors
23 determine shop requirements
failure
failure analytics floor 36
48 Capital forecasting
requirements
Real-time asset equipment asset
15 Rapid design
57 performance health diagnostic
Logistics and and failure prototyping
sensitive monitoring 10
Decision prevention through 3-D
Management In-process printing
shipment 38 traceability to Mixed reality
suite to monitoring to enable
ensure real- 9
aggregate 56
time visibility digital
35 32
45
Source: McKinsey & Company. Fourth Industrial Revolution scale-up engine, in collaboration with the World Economic Forum
A use case consists of applications of Fourth Industrial Revolution technologies (typically more than one in
combination) oriented to reinvent production processes and drive business value by solving specific production
problems. These can be across machining, assembly, maintenance, quality, supply chain, design, prototyping
and engineering.
What business value drivers do they contribute to?
– Speed to market
– Agility and responsiveness
– Resource productivity and efficiency
– Customization to customer needs
– Value-added services and business model innovation
Use cases have resolved problems across different areas of production and beyond the factory’s four walls.
Examples include:
Figure 8
Figure 8: Use case – automating and optimizing material selection in inventory management
Throughout the research, companies pioneering use cases are classified by value driver (speed to market,
technology adoption explained that technologies are agility and responsiveness, resource productivity and
driving more than just productivity: they are impacting efficiency, and customization to customer needs, as shown
quality, worker safety and sustainability, and creating in Figure 9). Underscoring their relevance and applicability,
other forms of business value in addition to enabling the 70% of the use cases from the compendium can be
company to better focus on innovation. In this sense, the deployed to enhance more than one value driver.
Speed to market
Agility
Agilityand
andresponsiveness
responsiveness
27 28 30 36
Expanded high-
End-to-end, real-time
performance computing Product-costing software Rapid, outsourced
supply chain visibility
to reduce product design- integrated into 3D design prototyping of metal parts
platform
2 2 3 3 life cycles
simulation 4 4 5 5
Real-time
Real-timelocating
locating
Light-guided
Light-guided
assembly
assembly Mixed
Mixed reality
reality
to to
enable
enable Mixed
Mixed
reality
reality
to to system
systemforfor
keykey
sequence
sequence digital
digital
standard
standard work
work accelerate
accelerate
training
training
times
times manufacturing
manufacturing
components
components
8 8 9 9 1010 1111
Predictive
Predictive
maintenance
maintenance Predictive
Predictive
maintenance
maintenance Predictive
Predictive
maintenance
maintenance
Predictive
Predictive
maintenance
maintenance
aggregating
aggregatingdata
data
from
from through
throughtemperature
temperature through
throughmachine
machine
through
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audio
monitoring
monitoring
historian
historian
systems
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monitoring vibrations
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monitoring
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2424 Digitized
2525 Digitized
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procedures
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line
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Mixed
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with
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and
andquality
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workflow
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end-of-line
end-of-line
inspection
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andandmultimedia
multimedia
sharing
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11 22 33 44
Cycle
Cycletime
timeoptimization
optimization
through
throughbig-data
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Light-guided
Light-guidedassembly
assembly Mixed
Mixedreality
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enable Mixed
Mixedreality
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analytics
analyticsononlines'
lines'
sequence
sequence digital
digitalstandard
standardworkwork accelerate
acceleratetraining
trainingtimes
times
programmable
programmablelogic logic
controllers
controllers
55 66 77 88
Real-time
Real-timelocating
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Machinealarm
alarm
Cost
Costoptimization
optimizationofof Predictive
Predictivemaintenance
maintenance
system
systemforforkey
key aggregation,
aggregation,prioritization
prioritization
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manufacturing
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andanalytics-enabled
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sensor
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Predictive
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Real-time
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2525Digitized
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procedures
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with Aggregate
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demand Automated
Automatedfieldfieldservice
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In-processtraceability
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integrated
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workflow across
acrossend-to-end
end-to-end parts
partsidentification
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and and
andquality
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and
andmultimedia
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suppliernetwork
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sharing
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3939
Single
Singleplatform
platformforforreal-
real-
time
timesupply
supplychain
chain
decisions
decisions
Speed to market
27 28 30 36
Expanded high-
End-to-end, real-time
performance computing Product-costing software Rapid, outsourced
supply chain visibility
to reduce product design- integrated into 3D design prototyping of metal parts
platform
simulation life cycles
Customization
Customization to customer
to customer needs
needs
17 17 18 18 23
23 29 29
Enterprise manufacturing
Enterprise manufacturingAutomated in-linein-line
Automated opticaloptical
RapidRapid
designdesign
prototyping
prototyping
Digital twintwin
Digital for remote intelligence
for remote system
intelligence to to inspection
system to replace
inspection to replace through 3D additive
production optimization upgrade operations end-product manual through 3D additive
production optimization upgrade operations end-product manual manufacturing
management inspection manufacturing
management inspection
35 35 38 38
Automation andand
Automation Part traceability from
optimization of manual Part traceability from
optimization of manual unique digital tag based
material selection and unique digital tag based
material selection and on surface scanning
inventory management on surface scanning
inventory management
Figure 10
Figure 10: Use cases by industry and cross-industry applicability
Applicable Non-applicable
Aerospace 32 7
Automotive 33 6
Construction 19 20
Consumer goods 28 11
Electronics 31 8
Energy 21 18
Pharmaceuticals 27 12
Transportation 17 22
Figure 11
Figure 11: Scale-up engine – framework for adopting technology
Source: McKinsey & Company, in collaboration with the World Economic Forum
“Changing mindsets from stage-gate innovation to agile thinking is an important driver of technology
transformation in production.”
Kurt Bock, Chairman of the Board of Executive Directors , BASF SE, Germany
The Fourth Industrial Revolution will lead to a new type Moreover, more specific efforts to diffuse and adopt
of competition between and within countries, along with technology, often aggregated under an umbrella national
growing uncertainties across manufacturing nations. programme, are on the rise. In the last six years, eight of
However, the latest technological developments represent the top 10 manufacturing countries have launched national
a concurrent opportunity for countries to accelerate efforts – best known as Industry 4.0 strategies – to capture
progress and transition towards the future of production. productivity gains and strengthen their position globally
for the future. The reasons behind this increased focus on
Most of the industrial companies consulted in 2017 agreed production, with technology as a key foundational pillar,
on government’s critical role in creating an enabling include the following:
environment and production ecosystem conducive to
the development, diffusion and adoption of technology. – Countries can potentially leapfrog their industrial
While industrial policy and strategy have existed for several development and journey to modernize by accelerating
decades, the focus in recent years has been on technology adoption of new technologies
and innovation, as governments try to keep pace with the – For industries to adopt technologies at scale, an
Fourth Industrial Revolution’s opportunities and challenges. enabling environment including infrastructure, IT
At the national level, policy-makers continue to work at connectivity and appropriate intellectual property laws
managing macroeconomic levers; namely, they look to must be developed
create market conditions favourable to manufacturing
– An economy’s success depends on promoting R&D&I
companies, to reinforce critical infrastructure (especially for
so that technology can be adopted and diffused at a
telecommunications and IT connectivity) and to develop
lower cost for large, medium and small enterprises
appropriate trade policies that support the market for
manufactured goods.
For the Technology and Innovation for the Future of
“The next generation of industrial strategy will have to Production project, over 20 countries’ efforts were
be holistic, drive innovation across the value chain and analysed, focusing especially on technology. In parallel,
keep pace with the new and emerging technologies for the Country Readiness for the Future of Production
all kinds of industries.” initiative profiled over 100 countries against key drivers of
production and current levels of readiness to successfully
Suresh Prabhakar Prabhu, Minister of Commerce and Industry of India transition towards the future of production. Examples
of mechanisms for diffusing technology, as used by the
countries analysed, are shown in Figure 12.
Recently, manufacturing has declined more rapidly in the United States than in other advanced economies.
While it makes up only 9% of employment and 12% of the country’s gross domestic product (GDP),
manufacturing drives 30% of US productivity growth, 60% of exports and 70% of private-sector R&D. Although
the largest US manufacturers have managed to thrive despite growing headwinds, SMEs have been hit hard.
This has implications for the broader economy, as manufacturing’s decline represents two-thirds of the fall in
labour’s share of US GDP and has limited the prospects of middle-income workers. Larger manufacturers are
also concerned because they face more risk without a healthy ecosystem of domestic suppliers to provide
agility and opportunities for collaboration. In addition, the US manufacturing sector has been slow to adopt
digital technologies, thus dragging down its productivity.
According to the McKinsey Global Institute, the United States could capitalize on its strengths to boost
manufacturing output by 14-20% by 2025. This is based on the impact of progressively higher adoption of
technology, export growth and share of domestic content in finished goods. The World Economic Forum
Country Readiness for the Future of Production project sees the United States as strongly positioned for the
future, scoring in the top five across all drivers of production, especially in innovation and technology.
Countries starting earlier on this journey differed in maturity manufacturing sectors to digital manufacturing. This
compared to countries that were lagging, based on initiative is part of the country’s long-term strategic vision to
detailed analysis of specific efforts and levers available to develop intelligent manufacturing to generate new growth
promote technology diffusion, adoption and innovation. and strengthen Chinese manufacturing. Russia became the
Pioneering countries have been able to shift their focus latest large economy to create a national programme by
from creating awareness on new technologies for their launching its Advanced Industrial Technologies in 2017. The
industries to building an institutional framework that Indian government launched the Make in India initiative,
supports the scalability of Fourth Industrial Revolution and is slated to come up with a revamped industrial policy
technologies. with a key focus on technology adoption. Many other
countries, including Australia, Canada and Spain, have also
Of the countries analysed, Germany was the first to launch started national-level programmes.
an Industry 4.0 programme (in 2011), followed by the United
States, Italy and France between 2012 and 2013. Asian As many of these efforts are in the early stages, a full
countries (South Korea, Japan and China) have kicked assessment of their impact is not yet possible. However,
off their national efforts more recently. China’s 2016-2020 some results already show that R&I projects are advancing
plan seeks to upgrade key areas of its 10 priority traditional manufacturing and increasing access to finance for SMEs.
02 Light-guided assembly
sequence
Variability in assembly
processes that also require long
▪ Developed light-based augmented reality (AR) display system that
guides operators on error-prone, manual part-picking process. It helps
training times to accelerate the off-line training of operators and also can be applied
to on-line assembly.
04 Mixed reality
to accelerate
Need to reduce training time and ▪ Developed new digital training instructions that overlay with real-
improve effectiveness of on-boarding world, on-the-job training environment through use of an AR helmet.
training times new shop-floor workers
▪
05 Real-time locating
system (RTLS) for key
Production times extended due
to time wasted searching for
Deployed a solution allowing workers to easily find all in-process
parts in a highly customized production environment through sensor-
manufacturing parts based RTLS at custom automotive manufacturer.
components
FACTORY FLOOR: ASSEMBLY AND MACHINING USE CASES
06 Cost optimization Reduce pumping operating ▪ Leveraged sensor to identify the key cost parameters and optimize
of heavy operations costs them to reduce the costs associated with salt water disposal.
through sensor analysis
08 Predictive maintenance High maintenance costs ▪ Developed a time-series data analytics solution that rapidly
aggregating data from to analyse equipment performance streamlines asset modelling, receiving data from multiple data
historian systems (e.g. failure root-cause analysis, points across the historian systems.
benchmarking costs across original ▪ This data can be used in a model to forecast equipment failure.
equipment manufacturers)
09 Predictive maintenance Machine downtime/ ▪ Monitored audio signals of over 100 machines and forecasted
through audio monitoring excessive maintenance cost machine maintenance requirements to minimize downtime.
▪
10 Predictive maintenance
through temperature
High downtime costs of
equipment, strengthening the
Developed an engine to generate real-time insights and alerts on
critical equipment, based on the relevant sensor data (e.g. gearbox
monitoring need to anticipate failures early temperature and vibration).
on ▪ Applied a predictive model to the engine to drive anticipated
maintenance actions before expected failures.
▪
11 Predictive maintenance
through machine
High maintenance costs to
monitor vibration across large
Installed remote vibration sensors in the energy plant's critical equipment
(e.g. water injection pumps) to facilitate consistent data collection. The
vibrations monitoring facilities for preventive actions sensor data was connected to a machine-learning engine to calculate
alerts for unusual activity in the equipment that could result in a
breakdown. Alerts and real-time results were visualized in a multi-
platform app to increase visibility on the equipment's health.
▪
12 Predictive maintenance
using historical data from
High downtime costs of
equipment, strengthening the
Installed a multivariate engine, based on collected and analysed data, to
clearly represent the signals and elements predictive of adverse events.
downhole instrumentation need to anticipate failures early This engine was used to repair or replace equipment before its failure
on and to modify the operating conditions of the moving systems (e.g. lifts)
to extend the life of the critical equipment.
▪
13 Real-time pipeline cost
optimization based on
High maintenance costs of
pipelines to maintain the
Deployment of an edge solution that uses installed sensors to monitor
and analyse data in real-time and allow for proactive decisions (e.g.
edge sensors required uptime levels shutting down a valve) based on predictive models. The edge solution
allowed to deploy a data analytics solution in remote assets where
transporting data was expensive and unreliable.
▪
14 Remote assistance using
augmented reality
Complex operations (e.g.
machine set-up) requiring
Implemented a solution that allows operators and technicians to
connect through tablets with remote experts who can provide guidance
presence of expert(s) through audio and written comments, or via drawings over the
visualized images in real-time.
16 Digital dashboards to
monitor overall equipment
Low shop-floor productivity due
to ineffective analysis of key
▪ Built digital dashboards with operator and supervisor performance
dashboards (OEE, downtime analysis, quality losses, changeover
effectiveness (OEE) performance indicators (KPIs) duration) based on captured PLC data.
18 Enterprise manufacturing
intelligence (EMI) system
Growing complexity in the product
variants, requiring more advanced
▪ Installed an EMI system with over 400 IoT devices (sensors). The
system allowed for real-time monitoring and the display of results,
to upgrade operations production management predictive intelligence for maintenance and quality, and partial
management traceability.
19 Integration platform to
connect machine-level
High manufacturing costs and
lack of an integrated view of real-
▪ Deployed a platform for a real-time production monitoring system,
combining data captured across the shop-floor functions, ERP and the
data with enterprise time operational performance to manufacturing execution system.
software allow effective problem-solving ▪ This platform allowed for improved issue resolution by maintenance
and resolution and engineering. It also enabled creation of a new digital performance
management system that displayed real-time operating results with
end user-adapted cockpits (e.g. operator, team leader, manager).
20 Real-time asset
performance monitoring
High maintenance costs for
monitoring transformers via
▪ Deployed a cloud-based solution, connected to any mobile device,
to monitor real-time performance of all integrated assets in the
and visualization routine manual samples power plant.
21 Sensors-based
manufacturing KPI
Low shop-floor productivity due
to lack of data capture from
▪ Rapid installation of sensors to connect machines with ERP and
quality management systems for deploying KPI visualization
reporting equipment software, which generates reports with multi-platform access
(worker device, PCs) and enables continuous improvement.
25 Digitized standard
procedures for line
Inconsistent paper- based
procedures leading to lost
▪ Developed a digital standard operating procedure that runs on any
platform (e.g. mobile, tablet). The solution provided clear and visual
operations, with integrated productivity in manual processes instructions, recorded evidence of the results, reduced paperwork and
workflow and multimedia (changeover, start-up, line cleaning) shortened training time. The system included a mobile workflow
sharing collaboration portal platform to coordinate start-up and changeover process steps, as
well as audiovisual sharing (text, audio, photos, videos).
27 Expanded high-
performance computing
Long and iterative design
cycles due to lack of
▪ Reduced the iteration cycles in the design phase of a complex part by
leveraging additional computing capacity from a cloud-based, high-
to reduce product design computing capacity performance computing provider.
simulation life cycles
30 Rapid outsourced
prototyping of metal
Long and/or expensive prototyping
cycles of metal parts
▪ Outsourced metal prototyping of parts to a modern computer
numerically controlled (CNC) machining manufacturer. The external
parts vendor was able to quickly manufacture and ship the parts by
installing a plug-in to the designers' CAD software that checks the
manufacturability and price of the prototype and transmits the file
directly to its CNC machine.
31 Cost modelling to Lack of rapid and effective cost ▪ Implemented a product costing software to rapidly generate cost
support make-versus- analysis tools for purchasing analyses of parts (e.g. clean sheets) to inform make-versus-buy
buy decisions negotiations decisions and negotiations with suppliers.
32 Aggregate demand
across end-to-end
Delays in supply chain due to
poor communication of demand
▪ Deployed a material demand aggregation engine to map all parts used
across all the suppliers that deliver to all sites in the manufacturing
supplier network needs across network of sites and network. The engine grouped the common parts used at different points
suppliers in the process, monitored part purchase points and created visibility to
all tiers of suppliers.
34 Automated logistic
operations decision-
Labour-intensive logistics
planning
▪ Built a logistics and optimization app that mathematically models
human expertise in real time, recommending the best decision output
making based on priority and defined scoring.
37 In-process traceability
and quality
Quality problems across the
supply chain without integrated
▪ Created production traceability system to ensure product quality and
provide end-to-end supply chain visibility and analytics across multi-
visibility of performance plant network.
The full version of the scale-up engine includes details of the phases and activities on the journey to scale, details per
activity, exploration and assessment of key activities with real cases, and a compilation of key lessons learned by leading
executives/constituents. For the full version of the toolkit, or for more information, contact the Technology and Innovation
for the Future of Production team at the World Economic Forum.
Rally the
organization
Spark innovation
by demonstrating
the value at stake
Source: McKinsey & Company, in collaboration with the World Economic Forum
STRATEGY
Create a pipeline of Fourth Industrial Revolution technology use cases, driven by the
innovation team in collaboration with the business units
Design use cases and calculate the business case, identifying infrastructure requirements
and process enablers
Example
Assess the applicability of each use case and the impact maturity across business
units/sites
Example
1
McKinsey, McKinsey Global Institute, “A future that works: 14
Ibid.
Automation, employment and productivity”, January 2017. 15
BMW, “BMW uses digitalization to improve processes
Available at https://www.mckinsey.com/global-themes/digital- in production”, 11 August 2015. Available at http://www.
disruption/harnessing-automation-for-a-future-that-works. bmwblog.com/2015/08/11/bmw-uses-digitalization-to-
2
McKinsey, “Where machines could replace humans—and improve-processes-in-production/.
where they can’t (yet)”, July 2016. Available at https://www. 16
Siemens, “adidas and Siemens set to collaborate in the
mckinsey.com/business-functions/digital-mckinsey/our- digital production of sporting goods”, Press Release, 24
insights/where-machines-could-replace-humans-and-where- April 2017. Available at https://www.siemens.com/press/
they-cant-yet. PR2017040273DFEN.
3
McKinsey, “How to achieve and sustain the impact of digital 17
Microsoft, “ABB and Microsoft partner to drive digital
manufacturing at scale”, June 2017. Available at https:// industrial transformation”, News Center, 3 October 2016.
www.mckinsey.com/business-functions/operations/our- Available at https://news.microsoft.com/2016/10/03/abb-and-
insights/how-to-achieve-and-sustain-the-impact-of-digital- microsoft-partner-to-drive-digital-industrial-transformation/.
manufacturing-at-scale. 18
Acatech, “Industrie 4.0 in a Global Context: Strategies for
4
Ibid. Cooperating with International Partners”, Executive Summary
5
V. Zimmermann, “An international comparison of R&D: and Recommendations, 2016. Available at http://www.
Germany benefits from industrial research strength”, KFW acatech.de/fileadmin/user_upload/Baumstruktur_nach_
research, No. 105, 25 August 2015. Available at https://www. Website/Acatech/root/de/Publikationen/Projektberichte/
kfw.de/PDF/Download-Center/Konzernthemen/Research/ acatech_STU_engl_KF_Industry40_Global.pdf.
PDF-Dokumente-Fokus-Volkswirtschaft/Fokus-englische- 19
Ministry of Economy, Trade and Industry (METI) of
Dateien/Fokus-Nr.-105-August-2015-FuE-an-international- Japan, “METI Signed a Joint Statement Regarding Japan-
comparison.pdf. Germany Cooperation on IoT/Industrie 4.0”, Press Release,
6
U.S. Bureau of Labor Statistics, Manufacturing Sector: Real 28 April 2016. Available at http://www.meti.go.jp/english/
Output [OUTMS], retrieved from FRED, Federal Reserve Bank press/2016/0428_04.html.
of St. Louis, 27 November 2017. Available at https://fred. 20
Make in India, “Make in India: Sweden 2017”, 12-13 October
stlouisfed.org/series/OUTMS. 2017. Available at http://www.makeinindia.com/sweden.
7
Gartner, “Gartner Says 8.4 Billion Connected ‘Things’ Will 21
European Commission, “Test beds without borders: EU-
Be in Use in 2017, Up 31 Percent From 2016”, Press Release, Japan collaboration”, 19 March 2014. Available at https://
7 February 2017. Available at https://www.gartner.com/ ec.europa.eu/digital-single-market/en/news/test-beds-
newsroom/id/3598917. without-borders-eu-japan-collaboration.
8
Internet of Things Institute, “Drones, AR, and an IoT Survival 22
Kaspersky Lab, “Industrial cybersecurity threat landscape
of the Fittest: 10 Tech Trends for 2017”, 8 December 2016. in H1, 2017: Every third ICS computer under attack was
Available at http://www.ioti.com/iot-strategy/drones-ar-and- from manufacturing sector”, 28 September 2017. Available
iot-survival-fittest-10-tech-trends-2017. at https://www.kaspersky.com/about/press-releases/2017_
9
McKinsey, McKinsey Global Institute, “A future that works: industrial-cybersecurity-threat-landscape-in-h1-2017.
Automation, employment and productivity”, op. cit. 23
United Nations Conference on Trade and Development
10a
Outsourcing Magazine cited in Niccolls AND Dimes, “Back (UNCTAD), Data protection regulations and international data
To The Future… Of Outsourcing!”, 12 October 2017. Available flows: Implications for trade and development, UNCTAD/
at https://niccollsanddimes.com/2017/10/12/back-to-the- WEB/DTL/STICT/2016/1/iPub, United Nations, 2016. Available
future-of-outsourcing/. at http://unctad.org/en/PublicationsLibrary/dtlstict2016d1_
10b
Darrow Bow, “Fortune, UPS and SAP Push On- en.pdf.
Demand 3D Printing”, May 2016. Available at: http://fortune.
com/2016/05/18/sap-and-ups-3d-printing/
11
McKinsey, “Unlocking the potential of the Internet of
Things”, June 2015. Available at https://www.mckinsey.com/
business-functions/digital-mckinsey/our-insights/the-internet-
of-things-the-value-of-digitizing-the-physical-world.
12
Based on McKinsey’s Digital Manufacturing Global Expert
Survey.
13
McKinsey, “Unlocking the potential of the Internet of
Things”, op. cit.
During 2017, the project team has collaborated closely with at two regional meetings: Japan’s Society 5.0 and China’s
the World Economic Forum constituent base, composed Business Roundtable. Moreover, the team has ensured
of 45 industrial and technology solution providers, 25 the breadth of analysis across industries and regions by
government officials and more than 40 expert academics. incorporating the results from McKinsey’s Global Expert
Throughout the year, the project team conducted three Survey (over 300 respondents) and IoT Practitioners’
rounds of expert consultation with executives and Survey (over 100 respondents).
government representatives leading technology adoption
in production. The team presented its initial findings at the The perspective from technology pioneers has also been
Annual Meeting of the New Champions in the People’s at the core of the research, leveraging the expertise of chief
Republic of China, organized a “go-and-see” workshop in executive officers at 14 production technology partners.
Chicago, USA, and discussed the content of the research
Ajit Jillavenkatesa Senior Policy Advisor, Standards and NIST, U.S. Department of Public Sector
Digitalization Commerce
Anna Roy Economic Advisor Niti Ayog, India Public Sector
Antti Eskola Commercial Counsellor Ministry of Economic Affairs Public Sector
and Employment of Finland
Hasegawa Hiroshi Principal Deputy Director, Advanced Ministry of Economy, Trade Public Sector
Machinery and Industry of Japan
Igor Manhães Nazareth Director Ministry of Industry, Foreign Public Sector
Trade and Services of Brazil
Mark Weaver Manager Growth Centre Policy, Department of Industry, Public Sector
Industry Growth Division Innovation and Science of
Australia
Ramiro Gonzalez Puglia Economic Advisor to the Ministry of Production of Public Sector
Undersecretary for Foreign Trade of Argentina
Argentina
Ricardo Del Olmo Chief of Unit, Procurement Secretariat of the Economy of Public Sector
Hidalgo Mexico
Seema Gaur Economic Advisor Ministry of Electronics and Public Sector
Information Technology, India
Ulla Hiekkanen-Makela Head of Unit, Enterprise development Ministry of Economic Affairs Public Sector
and Employment of Finland
Vasily Nomokonov Executive Director and Member of the Sibur Private Sector
Management Board, Sibur, Russian
Federation
Andreas Kunze CEO KONUX Private Sector
Andrei Lesunovskii Senior Manager, Strategy Severstal Private Sector
Andrey Suvorov Head of Critical Infrastructure Protection Kaspersky Private Sector
(CIP) Business Development
Brian Ballard CEO Upskill Private Sector
Christoph Hausser Plant Manager, Germany P&G Private Sector
David Strauss Digital Technology Lead Nestle Private Sector
Project Team