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Flevy Management Insights Case Study
Operational Transformation for Chemical Manufacturing Firm in North America


Fortune 500 companies typically bring on global consulting firms, like McKinsey, BCG, Bain, Deloitte, and Accenture, or boutique consulting firms specializing in Service Design to thoroughly analyze their unique business challenges and competitive situations. These firms provide strategic recommendations based on consulting frameworks, subject matter expertise, benchmark data, KPIs, best practices, and other tools developed from past client work. We followed this management consulting approach for this case study.

TLDR The mid-size chemical manufacturing firm faced operational inefficiencies, rising production costs, and declining market share due to outdated technologies and increased competition. By implementing Lean Six Sigma and modernizing its service design, the organization successfully reduced production costs, regained market share, and improved customer satisfaction, highlighting the importance of Change Management and continuous improvement in achieving business objectives.

Reading time: 18 minutes

Consider this scenario: The organization is a mid-size chemical manufacturing firm in North America facing significant operational inefficiencies.

It is grappling with a 20% increase in production costs due to outdated equipment and a 15% reduction in market share due to increased competition from more technologically advanced firms. The primary strategic objective of the organization is to enhance operational efficiency and modernize its service design to regain market share and improve profitability.



The organization is a mid-size chemical manufacturing firm in North America dealing with operational inefficiencies and declining market share. Major internal challenges include outdated equipment leading to a 20% spike in production costs. Externally, intensified competition has resulted in a 15% market share decline. It appears the root cause may be the company's lag in adopting modern manufacturing technologies and process improvements. Additionally, internal resistance to change and inefficient processes are likely exacerbating these issues.

Strategic Analysis

Chemical manufacturing in North America is highly competitive, with significant pressures from both established and emerging players. We begin our analysis by examining the primary forces driving this industry:
  • Internal Rivalry: High, driven by numerous firms ranging from large multinationals to specialized niche players.
  • Supplier Power: Moderate, as there are limited suppliers for certain raw materials, but alternative sources exist.
  • Buyer Power: High, with large industrial clients having significant bargaining power due to their scale and options available.
  • Threat of New Entrants: Moderate, due to high capital requirements but relatively low regulatory barriers.
  • Threat of Substitutes: Increasing, with the rise of green and sustainable chemical alternatives.
Emergent trends include a shift towards sustainable and green chemicals, driven by regulatory changes and customer demand. Key industry changes include:
  • Increased demand for sustainable chemicals: Opportunity to innovate and expand product lines but risk of higher R&D costs.
  • Technological advancements in manufacturing: Opportunity to modernize production but risk of high initial CapEx.
  • Regulatory changes: Opportunity to lead in compliance but risk of increased operational costs.
A STEEPLE analysis reveals significant impacts from political, economic, and technological factors. Regulatory shifts towards sustainability are creating new market opportunities but also necessitate costly compliance measures. Economic conditions are leading to price sensitivity among buyers. Technological advancements offer pathways to efficiency but require substantial capital investment. Social trends towards environmentally friendly products are reshaping demand patterns.

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Internal Assessment

The organization has strong market knowledge and a skilled workforce but faces significant challenges in operational efficiency and technology adoption.

SWOT Analysis

Strengths include a skilled workforce and established market reputation. Opportunities lie in adopting new technologies and expanding product lines to meet the growing demand for sustainable chemicals. Weaknesses include outdated equipment and resistance to change. Threats involve intensified competition and regulatory shifts that could increase compliance costs.

Gap Analysis

A gap exists between the current outdated manufacturing processes and the advanced technological capabilities required to remain competitive. Another gap is in the cultural resistance to change, which hinders the adoption of new processes and technologies. Bridging these gaps will involve significant investment in technology and Change Management initiatives to foster a culture of continuous improvement.

Organizational Structure Analysis

The current hierarchical structure slows decision-making and impedes innovation. A flatter model would empower employees and improve responsiveness. The existing top-down approach may also create a disconnect between management’s strategic vision and on-the-ground realities. Adopting a more decentralized structure could bridge this gap, fostering cross-functional collaboration and faster implementation of strategic initiatives.

4 Actions Framework Analysis

1. Eliminate inefficient legacy processes that add no value. 2. Reduce layers of hierarchy to speed up decision-making. 3. Raise investment in new technologies and employee training. 4. Create new cross-functional teams to drive innovation and process improvements.

Strategic Initiatives

Based on the comprehensive understanding gained from the previous industry analysis and internal capability assessment, the management decided to pursue the following strategic initiatives over the next 12 months .
  • Technology Modernization: Invest in state-of-the-art manufacturing technologies to reduce production costs and improve efficiency. This initiative aims to lower operational expenses and enhance production capabilities. Requires significant CapEx and skilled personnel for implementation.
  • Operational Efficiency Program: Implement Lean Manufacturing principles to streamline processes and eliminate waste. Expected to improve production efficiency and reduce costs. Involves training programs and process re-engineering.
  • Service Design Innovation: Develop new, customer-centric service designs to better meet client needs. Aims to enhance customer satisfaction and loyalty. Involves market research and product development efforts.
  • Regulatory Compliance Enhancement: Strengthen compliance frameworks to meet new regulatory standards. Expected to mitigate risks and avoid penalties. Requires investment in compliance systems and staff training.
  • Market Expansion Strategy: Explore new geographical markets to diversify revenue streams. Aims to capture untapped market potential. Requires market research, local partnerships, and regulatory compliance efforts.
  • Change Management Program: Implement initiatives to foster a culture of continuous improvement and adaptability. Aims to reduce resistance to change and enhance organizational agility. Involves comprehensive training and communication plans.
  • Sustainability Initiative: Develop sustainable product lines to meet growing demand for green chemicals. Expected to open new market opportunities and enhance brand reputation. Requires R&D investment and collaboration with sustainability experts.
  • Customer Feedback Loop: Establish a robust feedback mechanism to continuously gather and act on customer insights. Aims to improve product offerings and customer satisfaction. Involves setting up feedback channels and data analysis systems.
  • Strategic Partnerships: Form alliances with technology providers and research institutions to stay ahead of industry trends. Aims to enhance innovation and reduce R&D costs. Requires identifying and negotiating with potential partners.
  • Employee Training and Development: Implement a comprehensive training program to enhance skills and knowledge. Expected to improve productivity and job satisfaction. Requires investment in training resources and development modules.

Service Design Implementation KPIs

KPIS are crucial throughout the implementation process. They provide quantifiable checkpoints to validate the alignment of operational activities with our strategic goals, ensuring that execution is not just activity-driven, but results-oriented. Further, these KPIs act as early indicators of progress or deviation, enabling agile decision-making and course correction if needed.


What gets measured gets managed.
     – Peter Drucker

  • Production Cost Reduction: Measure the decrease in production costs, indicating improved efficiency.
  • Market Share Growth: Track changes in market share to gauge competitive positioning.
  • Customer Satisfaction Score: Assess the effectiveness of new service designs and innovations.
  • Regulatory Compliance Rate: Monitor adherence to new regulatory standards to mitigate risks.
  • Employee Engagement Level: Evaluate the impact of the Change Management Program on organizational culture.
These KPIs provide insights into the effectiveness of strategic initiatives and help identify areas requiring adjustment. They ensure the organization remains aligned with its strategic objectives and can adapt to emerging challenges.

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Stakeholder Management

The success of the strategic initiatives hinges on the involvement and support of both internal and external stakeholders, including frontline staff, technology partners, and regulatory bodies.
  • Employees: Crucial for implementing new processes and technologies.
  • Technology Partners: Provide necessary technological expertise and support.
  • Regulatory Bodies: Ensure compliance with industry standards and regulations.
  • Customers: Provide feedback and validate service innovations.
  • Investors: Offer financial backing for strategic initiatives.
  • Suppliers: Ensure a steady supply of raw materials and components.
  • R&D Teams: Drive innovation and development of new products.
  • Marketing Team: Essential for promoting new services and products.
  • Local Communities: Impacted by the company's operations and sustainability efforts.
Stakeholder GroupsRACI
Employees
Technology Partners
Regulatory Bodies
Customers
Investors
Suppliers
R&D Teams
Marketing Team
Local Communities

We've only identified the primary stakeholder groups above. There are also participants and groups involved for various activities in each of the strategic initiatives.

Learn more about Stakeholder Management Change Management Focus Interviewing Workshops Supplier Management

Service Design Deliverables

These are a selection of deliverables across all the strategic initiatives.

  • Operational Transformation Plan (PPT)
  • Modernization Roadmap (PPT)
  • Cost Reduction Financial Model (Excel)
  • Service Design Innovation Toolkit (PPT)
  • Compliance Enhancement Guidelines (PPT)

Explore more Service Design deliverables

Technology Modernization

The implementation team leveraged the McKinsey 7S Framework and the Lean Six Sigma methodology to drive the Technology Modernization initiative. The McKinsey 7S Framework, which focuses on aligning seven key organizational elements (strategy, structure, systems, shared values, style, staff, and skills), was particularly useful in ensuring that all aspects of the organization were aligned with the modernization efforts. Lean Six Sigma, a methodology that combines lean manufacturing principles with Six Sigma's focus on quality and defect reduction, provided a structured approach to improving production processes and reducing waste.

The team followed this process:

  • Analyzed the current state of the seven elements (strategy, structure, systems, shared values, style, staff, and skills) to identify misalignments and areas for improvement.
  • Developed a comprehensive plan to align these elements with the modernization goals, including restructuring teams, upgrading systems, and enhancing staff skills through targeted training programs.
  • Implemented Lean Six Sigma principles to streamline production processes, reduce waste, and improve quality. This involved mapping out current processes, identifying areas of inefficiency, and applying Lean Six Sigma tools to optimize workflows.
  • Conducted regular reviews and assessments to ensure continuous improvement and alignment with the overall strategic objectives.
The implementation of these frameworks resulted in a significant reduction in production costs and improved operational efficiency. The organization experienced a 15% decrease in production time and a 20% reduction in defect rates, leading to higher product quality and customer satisfaction. Additionally, the alignment of organizational elements facilitated smoother transitions and better communication across departments.

Operational Efficiency Program

The implementation team utilized the Value Chain Analysis and Kaizen methodology to enhance operational efficiency. Value Chain Analysis, which involves breaking down the organization's activities to identify value-creating and non-value-creating processes, was essential in pinpointing inefficiencies. Kaizen, a Japanese philosophy of continuous improvement, provided a framework for making incremental changes that collectively lead to significant improvements.

The team followed this process:

  • Conducted a Value Chain Analysis to map out all activities involved in the production process and identify areas where value was not being created.
  • Prioritized activities for improvement based on their impact on overall efficiency and cost reduction.
  • Implemented Kaizen principles by encouraging employees at all levels to suggest and implement small, continuous improvements in their daily work.
  • Established cross-functional teams to oversee the implementation of Kaizen initiatives and ensure alignment with strategic goals.
The operational efficiency program led to a 10% increase in productivity and a 12% reduction in operational costs. Employee engagement improved as staff felt more involved in the continuous improvement process. The organization also saw a reduction in waste and better utilization of resources, contributing to overall cost savings.

Service Design Best Practices

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Service Design Innovation

The implementation team employed the Design Thinking framework and the Service Blueprinting approach to drive service design innovation. Design Thinking, which emphasizes human-centered design through empathy, ideation, and prototyping, was instrumental in developing customer-centric service designs. Service Blueprinting, a tool for visualizing service processes and identifying potential points of failure, helped in mapping out and optimizing the customer journey.

The team followed this process:

  • Conducted Design Thinking workshops to gather insights from customers and employees, focusing on understanding their needs and pain points.
  • Generated a wide range of ideas through brainstorming sessions and selected the most promising ones for prototyping and testing.
  • Developed Service Blueprints to map out the entire service process, identifying key touchpoints and potential areas for improvement.
  • Tested and refined service designs based on feedback from customers and frontline employees, ensuring that the new services met their needs effectively.
The Service Design Innovation initiative resulted in the development of several new services that significantly improved customer satisfaction. The organization saw a 25% increase in customer retention and a 30% boost in positive customer feedback. The new service designs also led to more efficient service delivery, reducing wait times and enhancing the overall customer experience.

Regulatory Compliance Enhancement

The team utilized the COSO Framework and the Risk Management Process to enhance regulatory compliance. The COSO Framework, which provides a comprehensive approach to internal control and risk management, was critical in ensuring compliance with regulatory standards. The Risk Management Process, which involves identifying, assessing, and mitigating risks, helped in proactively managing compliance risks.

The team followed this process:

  • Implemented the COSO Framework to establish a robust internal control system, ensuring all regulatory requirements were met.
  • Conducted risk assessments to identify potential compliance risks and prioritize them based on their impact and likelihood.
  • Developed and implemented risk mitigation strategies to address identified risks, including updating policies and procedures, and enhancing staff training.
  • Established a monitoring and reporting system to track compliance and ensure continuous improvement.
The Regulatory Compliance Enhancement initiative led to a 100% compliance rate with new regulatory standards, significantly reducing the risk of penalties and legal issues. The organization also saw improved operational transparency and accountability, contributing to better overall governance and risk management.

Market Expansion Strategy

The team leveraged the PESTEL Analysis and the Market Entry Strategy framework to drive the market expansion strategy. PESTEL Analysis, which examines Political, Economic, Social, Technological, Environmental, and Legal factors, was essential in understanding the external environment of potential new markets. The Market Entry Strategy framework provided a structured approach to entering new geographical markets.

The team followed this process:

  • Conducted a PESTEL Analysis to assess the external environment of potential new markets, identifying opportunities and risks associated with each market.
  • Prioritized markets for entry based on the results of the PESTEL Analysis and the organization's strategic objectives.
  • Developed detailed Market Entry Strategies for each prioritized market, including market research, local partnerships, and regulatory compliance plans.
  • Implemented the Market Entry Strategies, establishing a presence in new markets and monitoring performance to ensure alignment with strategic goals.
The Market Expansion Strategy resulted in successful entry into 3 new geographical markets, contributing to a 15% increase in revenue. The organization was able to diversify its revenue streams and reduce dependence on its existing markets. The comprehensive market entry plans ensured smooth transitions and minimized risks associated with entering new markets.

Change Management Program

The implementation team employed the ADKAR Model and Kotter’s 8-Step Change Model to drive the Change Management Program. The ADKAR Model, which focuses on Awareness, Desire, Knowledge, Ability, and Reinforcement, was useful in managing individual change. Kotter’s 8-Step Change Model, which provides a structured approach to organizational change, helped in driving large-scale transformation.

The team followed this process:

  • Implemented the ADKAR Model to manage individual change, ensuring employees were aware of the need for change, had the desire to participate, and possessed the knowledge and ability to implement changes.
  • Followed Kotter’s 8-Step Change Model to drive organizational change, starting with creating a sense of urgency and forming a guiding coalition.
  • Developed and communicated a clear vision for change, empowering employees to act on the vision and creating short-term wins to build momentum.
  • Consolidated gains and anchored new approaches in the organization's culture to ensure long-term success.
The Change Management Program resulted in a significant cultural shift within the organization, fostering a culture of continuous improvement and adaptability. Employee engagement and morale improved, and the organization was better positioned to implement and sustain strategic initiatives. The program also led to more effective communication and collaboration across departments, further enhancing organizational agility.

Sustainability Initiative

The team utilized the Triple Bottom Line framework and the Life Cycle Assessment (LCA) approach to drive the Sustainability Initiative. The Triple Bottom Line framework, which focuses on People, Planet, and Profit, was essential in ensuring a balanced approach to sustainability. The LCA approach, which assesses the environmental impact of products throughout their life cycle, helped in developing sustainable product lines.

The team followed this process:

  • Implemented the Triple Bottom Line framework to ensure sustainability initiatives balanced social, environmental, and economic considerations.
  • Conducted Life Cycle Assessments to evaluate the environmental impact of existing and new products, identifying areas for improvement.
  • Developed sustainable product lines based on the results of the LCA, focusing on reducing environmental impact and enhancing social benefits.
  • Engaged stakeholders, including customers and suppliers, in the sustainability efforts to ensure broad-based support and alignment.
The Sustainability Initiative led to the development of several new sustainable product lines, contributing to a 20% increase in sales. The organization also saw a significant reduction in its environmental footprint, enhancing its reputation as a leader in sustainability. The initiative fostered stronger relationships with stakeholders and positioned the organization for long-term success in an increasingly sustainability-focused market.

Customer Feedback Loop

The implementation team employed the Net Promoter Score (NPS) framework and the Voice of the Customer (VoC) approach to establish a robust customer feedback loop. The NPS framework, which measures customer loyalty and satisfaction, was useful in gauging overall customer sentiment. The VoC approach, which involves collecting and analyzing customer feedback, helped in identifying specific areas for improvement.

The team followed this process:

  • Implemented the NPS framework to measure customer loyalty and satisfaction, collecting feedback through regular surveys.
  • Utilized the Voice of the Customer approach to gather detailed feedback from customers, using methods such as interviews, focus groups, and online reviews.
  • Analyzed customer feedback to identify common themes and areas for improvement, prioritizing actions based on their potential impact on customer satisfaction.
  • Developed and implemented action plans to address identified issues, continuously monitoring and adjusting based on ongoing feedback.
The Customer Feedback Loop initiative resulted in a significant improvement in customer satisfaction, with the NPS score increasing by 20 points . The organization was able to identify and address key pain points, leading to enhanced customer loyalty and retention. The continuous feedback loop also provided valuable insights for ongoing service improvements and innovation.

Strategic Partnerships

The implementation team utilized the Strategic Alliance Framework and the Value Network Analysis to form and manage strategic partnerships. The Strategic Alliance Framework, which provides a structured approach to forming and managing alliances, was essential in identifying and establishing valuable partnerships. The Value Network Analysis, which examines the relationships and value exchanges within a network, helped in optimizing the partnerships for maximum value creation.

The team followed this process:

  • Implemented the Strategic Alliance Framework to identify potential partners, assess their strategic fit, and establish formal alliances.
  • Developed partnership agreements outlining roles, responsibilities, and value-sharing mechanisms to ensure mutual benefits.
  • Utilized Value Network Analysis to map out the relationships and value exchanges within the partnership network, identifying areas for optimization.
  • Established governance structures to manage and monitor the partnerships, ensuring alignment with strategic objectives and continuous improvement.
The Strategic Partnerships initiative resulted in the formation of several high-value alliances, contributing to a 15% increase in innovation and a 10% reduction in R&D costs. The partnerships provided access to new technologies, markets, and expertise, enhancing the organization's competitive position. The Value Network Analysis helped optimize the partnerships, ensuring maximum value creation and mutual benefits.

Employee Training and Development

The implementation team leveraged the ADDIE Model and the Kirkpatrick Model to drive the Employee Training and Development initiative. The ADDIE Model, which stands for Analysis, Design, Development, Implementation, and Evaluation, provided a structured approach to developing training programs. The Kirkpatrick Model, which evaluates the effectiveness of training programs at four levels (reaction, learning, behavior, and results), helped in assessing and improving training outcomes.

The team followed this process:

  • Utilized the ADDIE Model to develop comprehensive training programs, starting with analyzing training needs and designing targeted training modules.
  • Developed and implemented training programs, using a variety of methods such as workshops, e-learning, and on-the-job training.
  • Evaluated the effectiveness of the training programs using the Kirkpatrick Model, assessing participant reactions, learning outcomes, behavior changes, and overall results.
  • Continuously improved the training programs based on feedback and evaluation results, ensuring alignment with strategic goals and employee needs.
The Employee Training and Development initiative led to a significant improvement in employee skills and knowledge, contributing to a 20% increase in productivity. Employee engagement and job satisfaction also improved, as staff felt more supported and valued. The organization was better positioned to implement and sustain its strategic initiatives, with a more skilled and motivated workforce.

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Key Findings and Results

Here is a summary of the key results of this case study:

  • Reduced production costs by 15% through the implementation of Lean Six Sigma and modernization of manufacturing technologies.
  • Increased market share by 10% by entering three new geographical markets and enhancing customer satisfaction.
  • Achieved a 100% compliance rate with new regulatory standards, mitigating risks and avoiding penalties.
  • Boosted customer retention by 25% and increased positive customer feedback by 30% through service design innovation.
  • Improved employee productivity by 20% and engagement through comprehensive training and development programs.
  • Formed strategic partnerships that led to a 15% increase in innovation and a 10% reduction in R&D costs.
  • Developed sustainable product lines, resulting in a 20% increase in sales and a significant reduction in environmental footprint.

The overall results of the initiative were largely successful, with significant improvements in production efficiency, market share, and regulatory compliance. The modernization of manufacturing technologies and Lean Six Sigma implementation led to a notable reduction in production costs and defect rates, enhancing product quality and customer satisfaction. The service design innovation and customer feedback loop initiatives resulted in higher customer retention and satisfaction, contributing to market share growth. However, some areas did not meet expectations. For instance, the initial resistance to change slowed down the implementation of new processes, highlighting the need for a stronger focus on change management. Additionally, while the market expansion strategy was successful, the organization faced challenges in adapting to local regulatory environments, suggesting a need for more thorough market research and local partnerships. Alternative strategies could include a phased approach to change management to gradually build acceptance and more robust market entry plans to address local regulatory challenges.

Recommended next steps include continuing to focus on change management to further reduce resistance and enhance organizational agility. This can be achieved by implementing more comprehensive training and communication plans. Additionally, the organization should invest in ongoing market research and strengthen local partnerships to better navigate regulatory environments in new markets. Expanding the sustainability initiative to include more product lines and further reducing the environmental footprint will also be crucial. Finally, maintaining and enhancing the customer feedback loop will ensure continuous improvement in service design and customer satisfaction.

Source: Operational Transformation for Chemical Manufacturing Firm in North America, Flevy Management Insights, 2024

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