McKinsey & Company has released a report highlighting a significant performance gap between companies that scale artificial intelligence across their enterprise and those that limit AI to isolated pilots. The study, which surveyed 1,000 senior and midlevel executives across 696 manufacturing and service-sector businesses, reveals that while nearly 90% of organizations are experimenting with AI, only 7% have successfully scaled it across the entire enterprise.
Rahul Shahani, McKinsey Partner and leader of the firm’s Manufacturing and Supply Chain Practice in North America, explains that the full value of AI is realized not through experimentation alone, but through deep integration into core operational processes. Companies with AI embedded across multiple functions generate nearly double the profit margins of peers using AI in only a few departments. The three-year return on invested capital for these firms is more than five times higher.
The report emphasizes that operational excellence is a crucial complement to AI deployment. Leading companies combine advanced AI tools with robust management systems, clear operating principles, and disciplined execution. A notable example is Siemens’ Nanjing facility in China, a World Economic Forum Global Lighthouse Factory. By integrating digital twin capabilities with broader operational improvements, the site significantly increased throughput. The facility first tightened its operating backbone—integrating a manufacturing operations management system to govern data flows between virtual models and physical assets—before scaling the technology.
McKinsey’s findings underscore that technology alone is not enough; the operating model around it is equally important. Companies that have built advanced technology into their operational excellence achieve higher productivity increases than those relying primarily on manual or analogue systems. The report serves as a call to action for organizations to move beyond fragmented AI pilots and pursue enterprise-wide AI integration to capture substantial performance gains.




