25 to 40%
percent throughput uplift on constrained assets, achieved without major capex through debottlenecking and advanced scheduling
15%
reduction in maintenance costs and 30 percent cut in unplanned downtime via reliability-centered maintenance and AI-enabled failure prediction
Up to 20%
energy-intensity improvement by optimizing heat-integration networks and deploying real-time process analytics
How we partner
Four-wall transformation
We help our clients improve yield, labor productivity, energy efficiency, and quality within their plants. Our support ranges from quick-turn assessments to full implementation programs focused on delivering measurable results and building internal capabilities.Network and resource optimization
We conduct make-versus-buy assessments and manufacturing network planning to ensure production footprints are aligned with volume growth, flexibility, and cost goals.Production scheduling with OptiCycle
We help stabilize production and maximize throughput with time-based run strategies that cut safety and cycle stock by 10 to 15 percent, free one to two shifts per line, and trim operating costs by 5 to 10 percent.Digital and smart manufacturing
We work with our clients to embed digital and AI across operations, from real-time data capture and analytics to operator decision support and closed-loop control systems. We also help accelerate adoption through Kearney’s Digital Model Factory, where companies can prototype solutions and upskill teams.
Why Kearney?
At Kearney, manufacturing excellence is not an add-on; it has been a core pillar of the firm since our first plant‐productivity studies in the 1930s. Eight decades later, we continue to redefine what “good” looks like on the shop floor, combining proven lean practices with Industry 4.0 and generative AI solutions to unlock capacity, cut costs, and build lasting capability.
We are the leading operations consulting firm in the chemicals sector, with methodologies tuned to high-hazard, high-asset environments.
- More than 100 chemicals manufacturing projects delivered in the past five years across base, specialty, and formulated products
- More than 50 senior experts with backgrounds as plant managers, process engineers, maintenance heads, and HSE leaders
- Proprietary OPTANO and OptiCycle optimization engines, delivered as leave-behind software or managed services
- Top-tier client roster, with more than half of the world’s 50 largest chemicals companies partnering with us on plant performance
- Strategic alliances with industry bodies such as ACC, CEFIC, GPCA, and leading academic research centers
Our manufacturing consulting experts If you’re looking to improve site performance, build digital capabilities, or transform your manufacturing network, we can help. Our practical, results-oriented approach is backed by deep industry knowledge and a commitment to execution. Contact us to discover how we can help you define and deliver the next chapter of manufacturing excellence.