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Nick Mellors

PartnerSeattle

Leads operational transformations for advanced industrial companies, helping realize the great potential of workforces aided by the latest digital breakthroughs

Nick leads our manufacturing and supply chain work for advanced industrials clients based in North America. He has deep experience in helping clients in the aerospace and defense sectors, where he transforms highly complex production systems for clients looking to ramp up production rates, improve productivity, and increase stability and resiliency.

As a leader of McKinsey's Industry 4.0 work with a deep respect for the value of the front-line worker, Nick integrates digital and new technologies with traditional Lean to empower our clients to realize the potential of their workforces for long-term success.

Examples of his recent client work include the following:

  • leading a manufacturing transformation for a defense manufacturer to increase the production rate by 40%, enabled by digital performance management
  • shaping a manufacturing transformation for a shipbuilder to increase the bottleneck production rate by 50% through cross-functional Lean improvements
  • driving a manufacturing transformation for an aerospace manufacturer to reduce total assembly time by 40% while decreasing cost and improving quality
  • developing a footprint and supply chain network strategy for an aerospace manufacturer to create $200M+ value from consolidation and the adoption of new technology
  • helping a medical device manufacturer increase production rate by >50x during a shortage to provide life-saving products to patients in need
  • developing an Industry 4.0 roadmap for an automotive original equipment manufacturer (OEM) to decrease throughput losses by 35% and quality losses by 25%
  • optimizing inventory management for a defense manufacturer through Lean warehouse operations and inventory rationalization to free $100M+ of working capital

Published Work

Redeveloping legacy sites to boost global maritime industry capacity,” McKinsey & Company, November 2024

Charting a new course: The untapped potential of American shipyards,” McKinsey & Company, June 2024

Why flow matters most in highly complex manufacturing,” McKinsey & Company, May 2024

Harnessing generative AI in manufacturing and supply chains,” McKinsey & Company, May 2024

Transforming advanced manufacturing through Industry 4.0,” McKinsey & Company, June 2022

Education

Brown University
ScB, engineering

Kellogg School of Management at Northwestern University
MBA