Check out our FREE Resources page – Download complimentary business frameworks, PowerPoint templates, whitepapers, and more.







Flevy Management Insights Q&A
What emerging technologies are proving most effective for cost take-out in manufacturing operations?


This article provides a detailed response to: What emerging technologies are proving most effective for cost take-out in manufacturing operations? For a comprehensive understanding of Cost Take-out, we also include relevant case studies for further reading and links to Cost Take-out best practice resources.

TLDR Advanced Robotics, IoT, and AI & ML are leading technologies for reducing costs in manufacturing by improving Operational Excellence, efficiency, and quality control.

Reading time: 4 minutes


In the rapidly evolving landscape of manufacturing, C-level executives are consistently on the lookout for technologies that not only enhance operational efficiency but also significantly reduce costs. The relentless pursuit of Operational Excellence has led to the adoption of various emerging technologies. Among these, a few have proven to be particularly effective for cost take-out in manufacturing operations, including Advanced Robotics, Internet of Things (IoT), and Artificial Intelligence (AI) & Machine Learning (ML).

Advanced Robotics

The integration of Advanced Robotics into manufacturing operations has been a game-changer for cost reduction. These robots, equipped with sophisticated sensors, AI, and machine learning capabilities, can perform complex tasks with precision and flexibility. They are not just limited to repetitive tasks but can adapt to different scenarios, reducing the need for human intervention and thereby lowering labor costs. According to a report by McKinsey, organizations that have integrated advanced robotics have seen a reduction in production costs by up to 20%. These robots also minimize waste and improve quality control, further enhancing cost efficiency.

Real-world examples of advanced robotics include collaborative robots (cobots) that work alongside humans in assembly lines, and autonomous mobile robots (AMRs) used in material handling and logistics within manufacturing plants. For instance, automotive manufacturers like Tesla have heavily invested in advanced robotics, significantly reducing production times and labor costs while improving safety and quality.

For organizations looking to implement advanced robotics, it's crucial to conduct a thorough cost-benefit analysis, considering not only the initial investment but also long-term savings in labor, waste reduction, and productivity gains. Strategic Planning around workforce development and upskilling is also essential to maximize the benefits of advanced robotics.

Learn more about Strategic Planning Machine Learning Cost Reduction Quality Control

Are you familiar with Flevy? We are you shortcut to immediate value.
Flevy provides business best practices—the same as those produced by top-tier consulting firms and used by Fortune 100 companies. Our best practice business frameworks, financial models, and templates are of the same caliber as those produced by top-tier management consulting firms, like McKinsey, BCG, Bain, Deloitte, and Accenture. Most were developed by seasoned executives and consultants with 20+ years of experience.

Trusted by over 10,000+ Client Organizations
Since 2012, we have provided best practices to over 10,000 businesses and organizations of all sizes, from startups and small businesses to the Fortune 100, in over 130 countries.
AT&T GE Cisco Intel IBM Coke Dell Toyota HP Nike Samsung Microsoft Astrazeneca JP Morgan KPMG Walgreens Walmart 3M Kaiser Oracle SAP Google E&Y Volvo Bosch Merck Fedex Shell Amgen Eli Lilly Roche AIG Abbott Amazon PwC T-Mobile Broadcom Bayer Pearson Titleist ConEd Pfizer NTT Data Schwab

Internet of Things (IoT)

The Internet of Things (IoT) has transformed manufacturing operations by enabling a level of connectivity and data exchange that was previously unimaginable. IoT devices can monitor, collect, and analyze data from various points in the manufacturing process, providing insights that lead to more informed decision-making and, ultimately, cost reductions. According to Accenture, IoT can improve profitability by an average of 28.5% for organizations that fully leverage it in their manufacturing operations.

IoT applications in manufacturing range from predictive maintenance, which uses sensors to predict equipment failures before they happen, reducing downtime and maintenance costs, to real-time inventory management, which optimizes stock levels and reduces holding costs. For example, General Electric's Predix platform offers IoT solutions that have helped manufacturers predict equipment failures and optimize maintenance schedules, saving millions in operational costs.

Implementing IoT requires a robust IT infrastructure and a strategic approach to data management and analysis. Organizations must ensure data security and privacy are paramount, given the sensitive nature of the data collected. Additionally, training and development programs are necessary to equip employees with the skills to leverage IoT technologies effectively.

Learn more about Inventory Management Internet of Things Data Management

Artificial Intelligence (AI) & Machine Learning (ML)

AI and ML are at the forefront of digital transformation in manufacturing, offering unprecedented opportunities for cost reduction. These technologies can analyze vast amounts of data to identify patterns, predict outcomes, and make decisions with minimal human intervention. A PwC report suggests that AI could contribute up to $15.7 trillion to the global economy by 2030, with a significant portion of this value derived from enhanced productivity and reduced costs in manufacturing.

Applications of AI and ML in manufacturing include demand forecasting, which uses historical data to predict future product demand, allowing for more efficient production planning and inventory management. Quality control is another area where AI excels, with machine learning algorithms analyzing products in real-time to detect defects, significantly reducing waste and rework costs. Siemens, for instance, has implemented AI-based systems in its gas turbine manufacturing plants to predict and prevent equipment failures, improving efficiency and reducing costs.

For successful implementation of AI and ML, organizations need to invest in high-quality data and advanced analytics capabilities. It's also critical to foster a culture of innovation and continuous learning among employees to keep pace with rapidly evolving AI technologies. Strategic partnerships with technology providers can also accelerate the adoption of AI and ML, providing access to specialized expertise and cutting-edge solutions.

In conclusion, Advanced Robotics, IoT, and AI & ML are proving to be the most effective technologies for cost take-out in manufacturing operations. However, the successful implementation of these technologies requires not only significant investment but also a strategic approach to change management, workforce development, and data security. As manufacturing continues to evolve, organizations that can effectively leverage these technologies will gain a competitive edge through enhanced efficiency, reduced costs, and improved product quality.

Learn more about Digital Transformation Change Management Cost Take-out Production Planning

Best Practices in Cost Take-out

Here are best practices relevant to Cost Take-out from the Flevy Marketplace. View all our Cost Take-out materials here.

Did you know?
The average daily rate of a McKinsey consultant is $6,625 (not including expenses). The average price of a Flevy document is $65.

Explore all of our best practices in: Cost Take-out

Cost Take-out Case Studies

For a practical understanding of Cost Take-out, take a look at these case studies.

Operational Efficiency Enhancement in Aerospace

Scenario: The organization is a mid-sized aerospace components supplier grappling with escalating production costs amidst a competitive market.

Read Full Case Study

Cost Efficiency Improvement in Aerospace Manufacturing

Scenario: The organization in focus operates within the highly competitive aerospace sector, facing the challenge of reducing operating costs to maintain profitability in a market with high regulatory compliance costs and significant capital expenditures.

Read Full Case Study

Luxury Brand Cost Reduction Initiative in High Fashion

Scenario: The organization is a high-end fashion house operating globally, facing mounting pressures to maintain profitability amidst rising material costs and competitive pricing strategies.

Read Full Case Study

Cost Reduction Initiative for Maritime Shipping Leader

Scenario: The organization in question operates within the maritime industry, specifically in the shipping sector, and has been grappling with escalating operational costs that are eroding profit margins.

Read Full Case Study

Inventory Rationalization for Telecom Retailer

Scenario: The organization is a leading telecom retailer grappling with escalating inventory costs and a complex product assortment that hinders optimal inventory turnover.

Read Full Case Study

Cost Reduction Initiative for Electronics Manufacturer in Competitive Market

Scenario: The organization in focus operates within the highly competitive electronics sector, continually pressed to innovate while managing costs.

Read Full Case Study

Explore all Flevy Management Case Studies

Related Questions

Here are our additional questions you may be interested in.

How are advancements in data analytics transforming the approach to cost management and operational efficiency?
Advancements in data analytics are revolutionizing cost management and operational efficiency by enabling predictive insights, data-driven process optimization, and enhanced decision-making, thereby fostering a resilient, agile, and competitive business environment. [Read full explanation]
How can businesses leverage data analytics in their cost reduction assessments to identify hidden cost-saving opportunities?
Businesses can leverage data analytics in cost reduction assessments to identify hidden savings by understanding cost structures, enhancing operational efficiency through process optimization, and driving strategic decision-making, thereby uncovering inefficiencies, forecasting trends, and making informed decisions that support sustainable growth and profitability. [Read full explanation]
What impact do emerging technologies have on traditional cost containment methods?
Emerging technologies like AI, ML, Blockchain, and IoT are transforming traditional cost containment methods, enhancing Operational Excellence, reducing operational costs, and fostering innovation across industries. [Read full explanation]
How can companies ensure that their Cost Take-out strategies do not negatively impact employee morale and company culture?
To ensure Cost Take-out strategies do not negatively impact employee morale and company culture, companies should prioritize transparent communication, involve employees in the process, strategically plan and implement cost reductions with consideration of their impact on work life and culture, and align efforts with the company's core values and culture, supported by leadership's behavior. [Read full explanation]
How can companies integrate cost reduction strategies with digital transformation initiatives to maximize benefits?
Integrating cost reduction strategies with digital transformation initiatives requires Strategic Alignment, leveraging Data and Analytics, and adopting best practices from successful real-world examples to enhance operational efficiency, drive innovation, and achieve long-term growth. [Read full explanation]
How are emerging technologies like AI and machine learning transforming cost reduction strategies?
AI and Machine Learning are revolutionizing cost reduction strategies by automating tasks, enhancing Operational Excellence, and driving data-driven decision-making, leading to significant financial savings and competitive advantages across industries. [Read full explanation]

Source: Executive Q&A: Cost Take-out Questions, Flevy Management Insights, 2024


Flevy is the world's largest knowledge base of best practices.


Leverage the Experience of Experts.

Find documents of the same caliber as those used by top-tier consulting firms, like McKinsey, BCG, Bain, Deloitte, Accenture.

Download Immediately and Use.

Our PowerPoint presentations, Excel workbooks, and Word documents are completely customizable, including rebrandable.

Save Time, Effort, and Money.

Save yourself and your employees countless hours. Use that time to work on more value-added and fulfilling activities.




Read Customer Testimonials



Download our FREE Strategy & Transformation Framework Templates

Download our free compilation of 50+ Strategy & Transformation slides and templates. Frameworks include McKinsey 7-S Strategy Model, Balanced Scorecard, Disruptive Innovation, BCG Experience Curve, and many more.