Realize the Potential of Manufacturing Digital Transformation

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We are in a time where most manufacturing leaders are seeking to digitally transform their production operations.

We believe that digital transformation to manufacturing 4.0 & beyond is about the pursuit of an autonomous, closed loop operating system (model) across the entire manufacturing footprint. Imagine every part, product and process connected to a digital twin, linked by IoT into an end-to-end digital thread. Automated systems capture metrics, flag bottlenecks and optimize solutions in real time, adapting and reacting to changes before they are visible to the human eye.

We use our industry-proven digital thread assessment & strategy methodology to help organizations transition from creating incremental benefit to driving transformational change with their digital initiatives.

Indicators you are Ready for our Manufacturing Assessment

  • Digital transformation program momentum stalling
  • Leadership increasingly impatient for digital transformation results
  • Funding for digital transformation program difficult to secure
  • Internal resources support is lacking
  • Proofs of concept successes are isolated and not programmatic
  • Program successes are a struggle to scale
  • Transformation objectives not aligned across corporate plans

Download the 2024 State of Smart Manufacturing Report

Benchmark your digital transformation strategy against 1,500 global leaders.

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Assessment Program Overview

Our digital manufacturing assessments are hypothesis-based studies designed to discover and curate potential future state opportunities. We offer a four, six and eight week program with a customizable deliverable list to meet your unique needs. Find examples of these deliverables below.


  • Interview guide & summary
  • Facility tour guide & summary
  • Information request & summary
  • Initial findings & implications

Assess & Prioritize

  • Maturity assessment and benchmarking
  • Use case prioritization matrix
  • Data science readiness assessment

Justify & Roadmap

  • Benefit, cost and ROI estimates
  • Future state roadmap
  • ROM benefits and costs for digital manufacturing roadmap
  • Case for change presentation


  • Target operating model
  • Conceptual architecture
  • Detailed phase 1 roadmap
  • Executive presentation, including next steps recommendation

"Kalypso helped us successfully drive a critical conversation about manufacturing digital transformation."

- CPG Digital Transformation Leader

Results Expected

  • Use cases identified and prioritized
  • Overarching value case and roadmap that contextualizes priorities and accelerates path to value
  • Funding secured
  • Cohesive vision grounded in business priorities
  • Executive alignment and sponsorship in place
  • Program resourced
  • Roadmap guiding the work
  • Agile methodology effectively utilized
  • Change management work stream imbedded in program
  • Scalable platform for change, including IT/OT architecture, organizational structure and partner network

The Kalypso Difference

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Unique blend of strategists, industry experts, technologists and organizational change specialists to serve as an end-to-end partner for your digital transformation journey, from strategy development through implementation and sustainment.

Digital Icon Customer Experiences

Open architecture, driven by desired business outcomes and defined through IT/Operations collaboration. Our partner ecosystem has a comprehensive set of capabilities for your digital journey, including 500+ licensed products spanning hardware, software and services.

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Industry proven methodology & playbook with 50+ modules supported by proprietary tools and accelerators.

  • Use case library
  • Benchmark database
  • Maturity model
  • Reference architecture
  • + many more
Background image: Case Slide Protein CPG
Case Study / $40B Protein CPG Company

Case Study / $40B Protein CPG Company: Transforming Manufacturing Capabilities with Digital

  • Defined and prioritized 35+ digital use case opportunities

  • Assessed Industry 4.0 digital manufacturing maturity

  • Developed a blueprint for the future roadmap for brownfield and greenfield sites

  • Identified priority use case to deliver a Minimum Viable Product (MVP)

A $40B+ protein CPG leader wanted to gain $1B in productivity gains over the course of 2 years by transforming their manufacturing capabilities with digital.

Kalypso conducted 3 plant tours and 30+ interviews to gain insights into the operations of the business and identify areas of improvement based on industry 4.0 standards.

Background image: Case Slide Paper Pulp
Case Study / $17B Pulp & Paper Company

Case Study / $17B Pulp & Paper Company: Transforming Maintenance to Improve OEE

  • Defined future state maturity targets across 32 dimensions spanning strategy, people, process, data & technology

  • Prioritized and developed a value case & roadmap for ~10 opportunities

  • Documented $40+M in estimated savings opportunities related to downtime

A $17B pulp & paper company was looking to improve OEE (overall equipment effectiveness) by transforming their maintenance capability.

Kalypso partnered with client SMEs and cross-industry visionaries to develop a future state vision, maturity model and roadmap.

Let’s Get Started

Thought Leaders

Steve Headshot 1 July 2022 Compressed
Principal and Global Practice Leader, CPG