Case Studies


Strategic Improvement Planning

CGN was approached to develop and implement a streamlined integration process to convert aftermarket parts supporting over 6,000 "in-field operational" machines.
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Data Cleansing

This project began due to the manufacturers inability to gain a meaningful view of its consolidated inventory.
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eBusiness Transformation

The eBusiness department was created by one of our Fortune 100 clients, with a goal to accelerate their overall growth in revenue.
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Production and Operations Improvement

Industry consolidation pressured a US food manufacturer to significantly cut costs.
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Supply Chain Modeling

CGN was sought out to evaluate inventory stock options between manufacturing facilities and all global distribution centers.
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Organizational Transformation

CGN developed an execution plan for the largest single location dealer of recreational vehicles in the Southeast United States.
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Parts Conversion

Implemented a new parts conversion process during a company merger.
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Aftermarket Parts Integration

A leading heavy equipment manufacturer acquired another manufacturer in 2011, expanding its product portfolio.
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Healthcare

A multi-billion dollar health system in the US is pondering a strategy to introduce a “fully owned, independently managed” subsidiary, taking their non-core services to the market.
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Supply Chain Transformation and Optimization

Due to a harsh downturn in economic conditions, a global Fortune 100 heavy equipment manufacturing company was challenged to streamline fragmented raw material networks in the company’s U.S. Midwest flow.
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Quality Transformation and Problem Solving

The client, a world leading bike components company, has embarked on a journey of quality transformation.
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Product Quality - Problem Solving

A large mining heavy equipment manufacturer was challenged to improve product quality and reliability during a tumultuous industry downturn.
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Supply Chain Transformation

A multi-billion dollar client’s autonomous hauling system is an emerging business, poised for growth with planned offerings for several machine products. While there is an existing supply network for certain system products, solutions for other mining products are being designed and developed. The client tasked CGN Global, with conducting a comprehensive review of their existing supply chain, and identifying redesign opportunities that create a lean and effective supply chain network, fulfilling the upcoming demand requirements.
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Supply Chain Competitive Analysis

A multi-billion dollar, global manufacturer was experiencing pricing pressures in foreign markets and product sales starting to erode. A competitor aggressively targeted specific global regions, and prices were as low as 30% cheaper. The client wanted to understand the competitors value chain and obtain a proper assessment of the competitors product cost.
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A Step Back to Stride Forward

Until 2012, Lexon had been using an internally developed web application for the company’s bond processing needs. Lexon decided to move to a leading custom desktop application, available in the market for bond processing. Moving to the desktop application did, however, present some challenges for Lexon business users. There were complex data and processing issues after the implementation that led Lexon to rethink their decision.
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Production & Operations Improvement

A multi-billion dollar client needed assistance achieving its 2015 build plan for a building construction product line that called for a 200% daily production increase. To achieve this, the client and CGN Global launched a Zone Offense, bringing critical functions together to jointly identify root causes, develop robust solutions, execute and eliminate constraints under strong governance and collaboration.
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Strategic Improvement Planning

CGN Global (CGN) worked collaboratively with stake holders and subject matter experts at an industrial service provider to assess a new parts management initiative and define go-to-market strategy based on an understanding off the value provided, with an overall objective of developing a Strategy Roadmap for a long term transformation.
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Organizational Change Management

A multi-billion dollar client’s mining division made significant improvements in its aftermarket parts integration process, and sought help from CGN Global (CGN) to develop training materials and a “simulated work environment” exercise to provide hands-on training for mining executives and the parts conversion team.
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Modeling Supply Chain Responsiveness

A heavy equipment manufacturer was lagging behind the competition in product availability to customers. The product line was producing low volume, highly customized equipment with over 100 possible configurations.
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Surety – Insurance Industry

In the risk services department of a major insurance client, surety serves as a major revenue generator with an estimated 90 million in the U.S.
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Supplier Strategic Improvement Planning

A major manufacturer was looking to expand its global supplier base in China and had found a supplier that they were interested in partnering with.
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Strategic Improvement Planning

In an ongoing effort to improve collaboration CGN needed to work with a client’s critical suppliers to establish a Sales & Operations Planning Process (S&OP).
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Strategic Improvement Planning

A supplier had recently completed a value stream transformation, led by the CGN Global team in which past due backlog was eliminated and shipping performance improved to greater than 95%.
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Risk Mitigation & Contingency Planning

A heavy manufacturing client was interested in shifting their global strategic footprint away from high cost locations, which resulted in union strikes.
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Production & Operations Improvement (PPM Reduction)

A major manufacturing company had a vision of developing themselves internally as well as developing their suppliers.
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Production System Improvement

A large steel castings supplier for a major manufacturing company was challenged with a history of lagging, poor shipping performance metrics, and Parts Per Million metrics.
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Problem Solving

A major manufacturing company was having issues with the production and operations in the assembly line of their engine products.
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Problem Solving

A major manufacturer enlisted the help of CGN to work with a supplier in their European division identified as being in need of performance improvement.
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New Part Introduction (PPAP)

A major gear manufacturer wanted in 2010-2015 to become a world class supplier in China.
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Supplier Performance Improvement - Lean Operations Implementation

A fabrication supplier was challenged to grow their business by 15-25% so that they could be slotted for a spot in a ‘favored supplier program’ of a global manufacturing customer.
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Supplier Performance Improvement - Lean Operations Implementation

The client was facing performance issues resulting in a 22% increase in past due pieces affecting their shipping performance target and creating a 91% gap from their quality goal.
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Supplier Performance Improvement - Lean Operations Implementation

A client was having issues with past dues over 699 pieces, supplier shipping performance at a 25% completion rate and PPM was 1,651 at an enterprise level.
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Harnessing Big Data to Provide Solutions

A multi-billion dollar client needed help with categorizing parts to strategically source to the right suppliers, reduce supplier proliferation, have the right parts at the right supplier, and optimize total cost.
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Growth Strategy Business Analytics

A major insurance client wanted to become highly profitable and increase their sales to customers by harnessing ‘Big Data’ and grow the value of their company to shareholders.
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Supply Chain Division of Global Engine Manufacturer

CGN helped deploy a sustainable capacity management framework that would allow a streamlined capacity ramp up and capacity management across the global facilities.
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Government Information System

CGN teamed with a government agency to develop a web-based immunization tracking system enabling healthcare providers to securely manage and use patient immunization data.
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Customer Information System

For a major agriculture client CGN developed a Customer Information System that holds customer profile, market share, dealer categorization, and competitive dealer information.
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Complexity Rationalization

CGN helped develop a financial model to measure the cost of business complexity and understand the true cost and margins associated with their product line(s).
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Rental Operations Management System

A multi-billion dollar engine and heavy machinery manufacturer and rental services client wanted to measure, analyze, and store rental service performance history information for the organization and its dealerships.
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Defect Reduction Analysis

CGN helped our client determine the theoretical best case level of quality and then helped them understand how their current quality improvement initiatives can contribute towards reaching that desired level.
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Warranty Cost Reduction

CGN helped our client gain visibility to high frequency, high cost warranty items through - mining of key customer warranty data, prioritizing of problems and defining critical implementation projects.
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Digital Dashboard Program Assessment Tool

An automotive OEM wanted to centralize and standardize their program "health" status reporting against milestones.
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Product Platform Cost Analysis and Reduction

CGN helped our client identify cost reduction opportunities on their high-volume product platform resulting in significant annual savings.
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Product Visualization

CGN helped this large manufacturing client build a product visualization environment within the context of its corporate web portal resulting in an easy-to-setup, thin-client solution that streamlined the publishing of multimedia-rich marketing content.
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Forest Product Machine Program

CGN developed a cost predictive model for the specialty products division of a heavy industrial equipment manufacturer. The simulation model incorporated associated program cost reduction initiatives to help determine the probability of achieving the projected cost reductions and analyze the origin of any cost variations.
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Enterprise Level NPV Analysis of Tier IV Program

CGN developed a NPV analysis simulation model for our client as they prepared to reengineer their entire product line in six years to meet stringent EPA and EU regulations (Tier IV Program).
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Defects per Million (DPM) and Warranty Risk Mitigation Program

CGN teamed with our client to develop a database tool that allows for modeling the controls and their potential effects.
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Strategic Sourcing - Spend Analysis

CGN provided our client with the tools needed to understand their worldwide spending.
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Multi-Variable Optimization

Our client needed the means to optimize engine test data for various optimization goals.
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Budgeting Process Automation

A division of a large equipment manufacturer needed a way to understand their budget projections.
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New Product Introduction Accounting Consultation

CGN provided consulting services to create cost roll-ups and analysis for New Product Introduction programs.
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HR Organization Assessment & Development

CGN conducted a functional assessment of the HR organization and assisted HR in transforming from an administrative organization to a strategic organization that focuses on talent management and driving a company culture of high performance.
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Global Footprint Optimization

CGN optimized this client’s global manufacturing and distribution footprint and supply chain organization, delivering cost savings that exceeded project goals.
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IT Organization Study & Implementation Support

CGN conducted an in-depth IT organization study to create an IT organization that would be a key driver and contributor to a new business strategy for the company.
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Training Summit – Push to Pull Implementation

A CGN Consulting team worked with the Lean, Six Sigma Consulting Division to accelerate the deployment of pull replenishment in a consistent manner across multiple global locations.
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Financial Reporting Area Study

CGN conducted and organizational assessment for an insurance company’s financial reporting area and provided process, technology, organization structure, and culture recommendations for attaining productivity improvements and cost savings.
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Organizational Assessment & Feasibility Study

A CGN Consulting team conducted an organizational assessment and feasibility study to determine whether the creation of a product and process development center would resolve current challenges and improve efficiency and effectiveness.
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International Retail Expansion

A CGN Consultant led international human resources for creation of a new international division and its rapid expansion.
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Special Investigations Fraud Process

A CGN Consulting team worked with the nationwide offices of the Special Investigations Unit within the Claim organization to improve identification and prevention of multi-state claim fraud.
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Vision, Strategy, and Culture Transformation

CGN worked with the executive leadership team to create a new corporate vision, develop strategic plans, and transform a highly engrained and dysfunctional culture.
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Engineering Workforce Competency Analysis

CGN conducted an engineering workforce competency analysis to identify critical competencies, assess current state capabilities within the engineering workforce, and provide recommendations for closing competency gaps.
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Career Management & Succession Planning Process

CGN worked with a Fortune 100 client to create a visual career management and succession planning tool.
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Purchasing – A New Way Initiative

A CGN Consultant led a project to establish strategic supplier collaboration across autonomous operating companies.
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Org Design and Governance Framework

CGN assisted the client with realigning itself with the needs of its customers and dealers by developing a new organization design, operating model, and governance framework for the client’s IT business unit.
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Strategic Portfolio Assessment and Alignment

CGN assisted the client’s technology division with identifying, assessing, consolidating, and aligning product development initiatives across the enterprise.
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Customer Information System

A major agriculture client wanted an application to manage customer data; query and download targeted customer lists, and provide a personalized portal for its dealers.
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Business Process Improvement

CGN assisted a publishing organization within this major manufacturing client to develop a cost effective strategy for information delivery while establishing internetworking between disparate publishing processes within the organization.
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Project Management Office

CGN assisted the client in implementing a project office for centralizing tracking and reporting information.
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Project Office Setup and Implementation

CGN helped our client build a prototype project/program office that effectively managed lab activity prioritization resulting in a proactive management of resources and streamlined project execution.
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Rental Operations Management System

A multi-billion dollar engines & heavy machinery manufacturer and rental services client wanted to measure, analyze, and store rental service performance history information for the organization and its dealerships.
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Defect Reduction Analysis

CGN helped our client determine the theoretical best case level of quality and then helped them understand how their current quality improvement initiatives can contribute towards reaching that desired level.
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Product Introduction – Modeling Analysis

CGN helped our client review and analyze a product introduction process to understand areas of improvement and to streamline the process to help achieve cost and cycle time targets.
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Change Readiness Improvement

CGN developed the engineering change readiness system for the engine operations division of a heavy equipment manufacturer. CGN rapidly developed a system that supports engineering, operations, and logistics in an environment processing thousands of engineering changes per year across several product platforms.
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Automotive Safety Crash Test Request & Data Acquisition System

An automotive OEM wanted to streamline their "safety crash testing" process to remove waste and inefficiencies being caused by outdated systems and manual processes, and increase the accuracy of their real-time data acquisition.
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Warranty Cost Reduction

CGN helped our client gain visibility to high frequency, high cost warranty items through: mining of key customer warranty data, prioritizing of problems and defining critical implementation projects.
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Value Stream Mapping - Global Information Authoring & Delivery

CGN assisted the service and support division of this major manufacturing client in studying and reengineering the global information authoring and delivery process for all technical information.
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Rental Business Planning

CGN facilitated business planning sessions for client dealerships in order to help them plan the long-term growth of their rental equipment business.
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Rental Portfolio Management Solution

CGN implemented a Portfolio Management Solution for a rapidly growing organization, resulting in a first year Return on Investment of over 200%.
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Embedded Systems Software Asset Management

CGN helped the electronics division of a large manufacturing company architect a solution for managing software assets for embedded systems.
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Digital Dashboard Program Assessment Tool

An automotive OEM wanted to centralize and standardize their program "health" status reporting against milestones.
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ES Cost Reduction Program

CGN helped our client identify cost sources that could be eliminated or reduced to improve their average profit margin in one of their product families.
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Integrated Development Environment Solution

CGN helped the Electronics Division of a large manufacturing company develop an integrated development environment for embedded systems.
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Product Visualization

CGN helped this large manufacturing client build a product visualization environment within the context of its corporate web portal resulting in an easy-to-setup, thin-client solution that streamlined the publishing of multimedia-rich marketing content.
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Process Modeling & Analysis

CGN helped the product support division of this large manufacturing client determine organizational and process inefficiencies while analyzing different business scenarios in order to optimize resource allocation and minimize costs.
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Enterprise Level NPV Analysis of Tier IV Program

CGN developed a NPV analysis simulation model for our client as they prepared to reengineer their entire product line in six years to meet stringent EPA and EU regulations (Tier IV Program). The client was challenged with identifying the right compliant product mix to maximize the enterprise's NPV based on regulation constraints, production and sales costs, and price projections.
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Marketing Communications Group Study

CGN developed a business process simulation to conduct business simulation analysis for their clients. CGN identified the performance drivers and areas of inefficiencies and recommended feasible business solutions to reduce overall period costs and improve process effectiveness.
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60 Day Response

CGN worked with the client's management to develop a 60 day response for the dealerships, in regard to on-going issues preventing the department from delivering training material coinciding with the deployment of machinery.
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Value Stream Analysis - Electronic Delivery Process Of Service Manuals

CGN assisted the Service and Support division of a major manufacturer of agricultural and forestry equipment in conducting Value Stream Analysis of their information delivery process. The study identified opportunities to reduce the lead time by 50% and also developed process metrics.
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IT Business Unit & Governance Design

CGN developed a new organizational design and operating model for the client's new IT business unit, as well as the corporate governance framework to assure a successful implementation and continued strong performance.
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Quality Issue Mitigation through Better Quality Data

Our client's lack of timely information was not allowing them to make critical business decisions in an acceptable time frame.
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Defects per Million (DPM) and Warranty Risk Mitigation Program

CGN teamed with our client to develop a database tool that allows for modeling the controls and their potential effects.
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Project Governance Office Setup

CGN worked with our client's Global Service Learning Division to implement a project governance office.
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Systems Interaction Analysis for an Authoring Process

CGN improved our client's system maintenance capabilities by developing a system interaction relationship map between various systems that support the technical publications authoring process.
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Upgrade and Enhancement of Critical Criminal History System

CGN worked with a state agency to update their criminal history system to support current technologies along with incorporating functional enhancements.
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First Responder Credentialing

CGN helped our client develop a system for providing biometric smart card credentials to all first responders in the state of Illinois.
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Budgeting Process Automation

A division of a large equipment manufacturer needed a way to understand their budget projections.
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Strategic Portfolio Management

CGN's interactive Portfolio Management dashboard provided the CFO of a $10 billion organization the ability to continuously evaluate the financial impact of past and future project's allocation decisions to achieve cost management targets over a five year period.
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Salvaging A Distressed Project

CGN helped our client in getting a delayed project back on track through effective execution management techniques that resulted in notable increases in project velocity, team engagement, and customer satisfaction.
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Capacity Forecast Digitization

CGN analyzed and digitized a business need which allowed strategic business decisions to made at dealerships and allowed our client to prepare for the market's strategic direction.
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Engine Supply Chain Study

CGN developed elasticity models for an engine manufacturer to analyze their key supply chain drivers and the potential impact to the organization's bottom line.
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Process Deployment Methodology Adoption

Process deployment methodology enables large scale rollout of process & systems initiatives throughout a distributed enterprise cutting across typical change resistance and fragmented agenda of sales & delivery channels.
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Supply Chain Inbound Logistics Center Start-Up and Business Case Development

CGN assisted our client's Logistics Division in analyzing their key inbound supply chain operations in relationship to revitalizing an existing building.
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Strategy Development Initiative for Organizational Excellence

CGN worked with our client's Service Learning division's management to develop a strategy focused on dealer facing operations in alignment with their Critical Success Factors (CSFs).
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New Product Introduction Accounting Consultation

CGN provided consulting services to create cost roll-ups and analysis for New Product Introduction programs.
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Manufacturing Process Documentation

CGN worked with a client that was looking to create common manufacturing process standards for all its facilities and utilize common tools and techniques across these facilities.
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Product Introduction – Modeling Analysis

CGN helped our client review and analyze a product introduction process to understand areas of improvement and to streamline the process to help achieve cost and cycle time targets.
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Program Management for NPI Process

CGN helped our client manage a multi-million dollar new product development program to ensure the teams, deliverables, options, and schedule were optimized and in line with program benefits.
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Product Development Process Metrics Assessment

CGN helped our client streamline the adoption of Product Development Process initiatives across the enterprise by providing insight to the rationalization of different metrics and improving buy-in from business units across the enterprise.
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Establish Advanced Product Quality Planning (APQP) Requirements

CGN performed APQP mapping, documentation and NPI integration for our client.
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Preplanning For Multi-Tiered Product Development

Our client designs and manufactures large mechanical systems for infrastructure development and construction. CGN introduced a TeamPort approach to the core team responsible for total systems integration and control.
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New Product Introduction Accounting Consultation

CGN provided consulting services to create cost roll-ups and analysis for New Product Introduction programs.
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Analysis of Engine Product Architecture

CGN helped our client study the detailed engineering design interactions between engine elements to identify the areas of high design complexity, groups of highly interactive elements (clusters), optimal design sequences based on information flows, and aligned teams.
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Product Health Improvement

CGN entered into a multi-project relationship with a global manufacturer to reduce quality defects by 75% in a 4 month window by building a sustainable organization of rapid response black belts.
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Product Platform Cost Analysis and Reduction

CGN helped our client identify cost reduction opportunities on their high-volume product platform resulting in significant annual savings.
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Consolidated Supplier Relationship Management Initiatives for Scale

CGN worked with a Purchasing Division of our client to consolidate the supplier relationship initiatives into a manageable roadmap of phases designed for milestone progress tracking.
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6 Sigma Project for Identifying Sourcing Alternatives

Utilizing 6 Sigma techniques, CGN helped determine a sourcing strategy that leverages low cost country advantages while rationalizing the client's supplier base.
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Supplier Capacity Planning

Due to continued part shortages in manufacturing/assembly, our client had developed a 5 year capacity planning tool that needed to be communicated to Global Purchasing buyers and suppliers.
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Establish Advanced Product Quality Planning (APQP) Requirements

CGN performed APQP mapping, documentation and NPI integration for our client.
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Strategic Sourcing - Spend Analysis

CGN's Global Manufacturing Practice provided our client with the tools needed to understand their worldwide spending.
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Zone Offense Manufacturing Quality Improvement

CGN assisted this client in understanding, and mitigating high defect rates on a large construction equipment manufacturing line. CGN provided a comprehensive approach and framework to detect and reduce quality defects using a structured approach to gathering, prioritizing, and tracking issues.
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