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Comprehensive Approach to a Capacity Expansion Case?

capacity expansion case structure MECE
New answer on Oct 31, 2023
8 Answers
332 Views
Anonymous A asked on Oct 29, 2023

Hello,

I recently underwent an interview at one of the MBB firms where I encountered a capacity expansion case. Could you kindly evaluate the framework I utilized to tackle this case and provide insights on whether it encompasses all necessary aspects?

Demand Analysis:

  • Present Scenario: Examining the current market conditions and competitive landscape
  • Future Projections: Assessing the anticipated market growth and the trajectory of competition

Assessing Client's Existing Capabilities:

  • Current Capacity: Establishing a baseline understanding of the client's existing capacity
  • Operational Efficiency: Identifying potential bottlenecks that could hinder performance

Investment and Enhancement Strategies:

  • Expansion Costs: Estimating the financial requirements for capacity expansion
  • Productivity Enhancements: Strategizing for improvements in productivity

Identifying and Mitigating Risks:

  • Examining potential operational risks that may arise during the expansion process

I appreciate your time and look forward to your valuable feedback!

Thank you.

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Sidi
Expert
replied on Oct 29, 2023
McKinsey Senior EM & BCG Consultant | Interviewer at McK & BCG for 7 years | Coached 350+ candidates secure MBB offers

Hi!

It all boils down to the concrete question! If the question is: "Should we expand our capacity?", then this does not differ from any other strategic go- or no-go question (market entry, product maunch, etc. it is - at the core - all identical!). 

Rigorously thinking through business means that each element that you want to scrutinize needs to clearly relate back to the question that you want to address! This principle should form the basis of any structure. (And, by the way, since you have to repeat this process for every question, it makes absolutely no sense to "learn" and memorize frameworks.)

At the core, all strategic questions necessitate a more or less identical assessment:

Can the client create value or not?

Hence, juggling around with different frameworks, trying to map and match them to these questions is just demonstrating this fundamental non-understanding of the candidate. I will say it again and again: cases should be approached and solved from first principles!

  • One of these first principles is that you start EVERY case from the core question that you need to answer! This core question is the starting point of a rigorous logic tree, and each element that you want to analyze needs to clearly relate back to the core question! This principle forms the basis of any structure.
  • Another first principle is, e.g, to define the criterion or criteria that need to be met in order to anwer this core question in one way or another.

The big advantage is that this is making "frameworks" unneccessary for the structuring of cases! You need to learn and internalize the logic, then you have a bullet-proof toolbox under your belt, far more rigorous then a "framework-learning" approach.

Just one example below which I described in an earlier post. This is about capacity expansion and vertical integration. Please think it through - I hope you will realize that the same logic, centered around value creation, can be applied to a myriad of different situations that people often describe as "different case types" (new market, new product, m&a, etc.). It also works indepent of whether Profit is the primary objective or not. As long as the objective(s) is/are clear, the criterion to answer the core questions can be adapted accordingly. It can also easily applied to your outlined example!

EXAMPLE:

Question:

Our client is a large producer of PET. PET is a type of plastic that is used mainly for producing bottles, such as the ones you find in grocery stores. The main component of PET is PTA. Our client has a PET plant in the US and serves clients both in the US and Europe. They have made the decision to build a PET plant in Europe to be closer to the clients. They have asked you to evaluate whether they should also backward integrate and purchase a PTA plant and locate both plants next to each other.

Approach:

This is a strategic investment decision. A very clear approach would be:

1. Core Question: "Should the client invest into purchasing a PTA plant next to the new PET plant in Europe?"

2. Identify criterion to make this decision: The additional value we can create over the client's investment horizon has to be significantly higher than the investment cost. Moreover, the risks need to be manageable.

3. Compile base information: Purchasing Price of PTA plant / yearly operating cost of PTA plant if purchased / capacity of PTA plant vs. PTA need / investment horizon of client

4. Deep dive into the value bucket by means of a profitability tree: what are the levers of value here? Compare Scenario A (PTA plant in Europe) to Scenario B (no PTA plant in Europe). Probably the value lever lies on the cost side: how much savings potential due to decreased/eliminated transport costs? How much savings due to eliminated import tariffs? etc.

5. Calculate annual value (delta between Scenario A and B). If a PTA plant in Europe indeed increases annual profits by a certain amount, you then divide the purchasing price of the PTA plant by this additional yearly profit. This gives you the break even point (point in time after which the investment becomes profitable). If this point comes earlier than the investment horizon, then this is a beneficial investment and the client should proceed with the purchase (purely based on financials).

6. Don't forget to compile potential risks and mention them in your summary

Cheers, Sidi

_______________________

Dr. Sidi Koné 

(🚀 Ex BCG & McKinsey Sr. Project Manager, now helping high potential individuals join the world's top Strategy Consulting firms (McKinsey | BCG | Bain))

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Ian
Expert
Content Creator
updated an answer on Oct 30, 2023
#1 BCG coach | MBB | Tier 2 | Digital, Tech, Platinion | 100% personal success rate (8/8) | 95% candidate success rate

Hi there,

This is not a good framework (sorry)

First: We need to know the client question to help!

Imagine having this same answer for Tesla trying to expand their gagafactory production in Australia versus a workshop in Italy with highly-skilled workers struggling to find workers in order to increase their output.

Or, Ukraine trying to increase the production of tanks while being hit by missle from Russia.

Or, me trying to increase the “capacity” of my work/output.

See my point?

The QUESTION is the most important there. There is no generic framework for capacity increase. Rather, you need a customized framework for each one.

Your framework listed is OK but not really that good.

1) Why do we need demand analysis? Just ask right upfront: how much do we need to increase output by? Bucket done…therefore, it's a bad bucket (can be eliminated by a single clarifying question)

2) Assessing….of course…every project assesses things…but that's not what the client is paying millions of dollars to have you do

3) Nowhere have you actually talked about how we can increase capacity

4) Risks/mitigating actions is not a bucket

I'm sorry to be so direct, but this framework is generic, it is NOT objective-driven, it is NOT MECE, and it doesn't actually address our problem.

Please read this: https://www.preplounge.com/en/articles/how-to-shift-your-mindset-to-ace-the-case

And please read this AND watch the videos in both cases so you can see how to framework effectively:

https://www.preplounge.com/en/articles/candidate-led-cases-what-to-expect-and-example-cases

Here is a capacity constraint framework for a very SPECIFIC client prompt (shoemaker with worker constraints):

https://drive.google.com/file/d/1Lb9CH98VH6YSkIPhXEQn6XJYlx68FNG0/view?usp=drive_link

^have to request access

(edited)

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Raj
Expert
Content Creator
replied on Oct 30, 2023
FREE 15MIN CONSULTATION | #1 Strategy& / OW coach | >70 5* reviews |90% offers ⇨ prep-success.super.site | MENA, DE, UK

Your framework for tackling the case seems quite comprehensive and covers the key aspects that need to be considered.

Starting with the demand analysis, it's important to assess both the present scenario and future projections. Understanding the current market conditions and competitive landscape will provide insights into the demand dynamics. Additionally, evaluating the anticipated market growth and trajectory of competition will help in determining the need for capacity expansion.

Assessing the client's existing capabilities is a crucial step. This involves establishing a baseline understanding of the client's current capacity and identifying any potential bottlenecks that could hinder performance. It's important to consider operational efficiency and identify areas where productivity enhancements can be made.

Estimating the financial requirements for capacity expansion is an essential aspect. This includes evaluating the expansion costs and strategizing for productivity enhancements to optimize the investment. It's important to consider both the upfront investment costs and the potential return on investment.

Lastly, identifying and mitigating risks is a critical part of the framework. Examining potential operational risks that may arise during the expansion process will help in developing risk mitigation strategies and ensuring a smooth implementation.

Overall, your framework seems to cover the necessary aspects for tackling a capacity expansion case. It demonstrates a structured approach and highlights the key considerations. Just make sure to adapt the framework to the specific details of the case and ask relevant questions to gather more information.

I hope this feedback is helpful! If you have any further questions, feel free to ask. Good luck with your future interviews!

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Pedro
Expert
replied on Oct 30, 2023
30% off in April 2024 | Bain | EY-Parthenon | Roland Berger | Market Sizing | DARDEN MBA

This is not how cases work. It is impossible to give you feedback on your approach without knowing the question.

A good framework is TAILORED to the question at hand (or even better, developed specifically for the question and hand). 

While I can say that in general, it's a matter of: how much it costs to expand capacity vs. how much capacity you need (which can be a matter of how much you have vs. expected demand).

But there are so many variables there. Are there multiple expansion options? Is there an option to outsource? Can we manage demand? Is this a matter of high upfront CAPEX or just of margin optimization? 

Finally: cut the risks. You don't evaluate risks only at the end. Risks should be assessed in every part of your framework.

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Frederic
Expert
Content Creator
replied on Oct 31, 2023
ex Jr. Partner McKinsey |Senior Interviewer| Real Feedback & Free Homework between sessions|Harvard Coach|10+ Experience

I am missing the strategic perspective here, what's the strategic imperative for considering the capacity expansion in the first place? Is it a growth motivation, competitor response, motivation to benefit from scale economies? I'd always start with a bucket strategic imperative first and many interdependencies will flow from here.

Warm regards,

Frederic 

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Cristian
Expert
Content Creator
replied on Oct 30, 2023
#1 rated MBB & McKinsey Coach

High-level, this sounds like an ok way to approach a capacity expansion case.

But without knowing the actual case, it's difficult to give you feedback. 

A structure is good when it's relevant. It's great when it's tailored specifically to the client situation i.e., the prompt. 

Feel free to add the prompt or re-post the question and happy to provide a revised perspective.

Best,
Cristian

———————————————

Practicing for interviews? Check out my latest case based on a first-round MBB interview >>> SoyTechnologies  

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Alberto
Expert
Content Creator
replied on Oct 31, 2023
Ex-McKinsey Associate Partner | +15 years in consulting | +200 McKinsey 1st & 2nd round interviews

We need to know the question to assess your framework…

 

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Anonymous B replied on Oct 29, 2023

Just curious, which MBB was this at?

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Sidi gave the best answer

Sidi

McKinsey Senior EM & BCG Consultant | Interviewer at McK & BCG for 7 years | Coached 350+ candidates secure MBB offers
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