Breg’s Bold Transformation: Delivering Over 180% ROI with a Big Bang Replacement

When orthopedic medical device leader Breg decided to embark on a journey of transformation, it wasn’t just about implementing new software—it was about reimagining how the organization worked.

Faced with a disconnected patchwork of systems, disengaged employees, and a mountain of inefficiencies, Breg embraced an ambitious “big bang” approach to change. The results? Nothing short of revolutionary.

Here’s the story of how Breg achieved an 186% ROI in under two years, slashed product development time by 77%, and halved the time spent on quality document control—all while empowering their teams with a user satisfaction rate of 91%.

The Problem: A System Stuck in the Past

Breg’s product development and quality teams were battling a maze of antiquated processes:

• Over 20 disjointed systems—none of which talked to each other.
• Critical data locked in binders—accessible only to employees physically present at certain locations.
• A workflow so clunky it took two days, four systems, and three collaborators just to find basic part information.

This environment stifled efficiency, frustrated employees, and hindered Breg’s ability to quickly adapt to challenges like supply chain disruptions or employee turnover.

The Solution: A Big Bang Transformation

Recognizing the need for radical change, Breg adopted a holistic approach—powered by Propel’s single-platform Product Lifecycle Management (PLM) and Quality Management System (QMS).

This wasn’t a piecemeal update—it was an all-at-once overhaul designed to centralize data and processes across engineering, quality, and supply chain teams; streamline and automate workflows across the entire company for faster decision-making; and empower users with real-time access to the data they needed to do their jobs quickly and efficiently.

Three guiding principles shaped their success:

1. Think Big: Embrace a blank canvas mindset to design processes for scalability and sustainability. Rather than focus on systems already in place, the Breg team asked what a best-of-breed solution designed from scratch would look like.
2. Design for Users, by Users: Breg involved end users deeply in every stage of the design and testing process. This ensured that the final process would deliver real value to those users, and ultimately to the company.
3. Stay True to the Vision: A relentless focus on the ROI and transformative potential of the project kept the team aligned and motivated. Change can be difficult, so it’s important to remember the payoff at the end of the process.

Watch Breg’s presentation from Propulsion 2024, ”The Big Bang Approach to Success: Lessons from Breg’s PLM & QMS Transformation.”

The Results: Speed, Simplicity, and Satisfaction

Breg’s investment in transformation paid off with stunning results:

186% ROI in 13 months:
Propel quickly proved its value, with an ROI and payback period that are even more impressive considering the time spent upfront to define requirements and gather user inputs.

77% reduction in product development time:
Time to market for new products was drastically accelerated. This provides real benefits to the bottom line thanks to increased sales and pricing power.

50% decrease in time spent on quality document control:
Compliance became a streamlined, efficient process. This drove significant increases in productivity and cost savings.

91% of users reported feeling satisfied or highly satisfied:
Employees felt more empowered, with many citing newfound independence in their roles. Happy employees are key to building great products and improving the lives of patients.

These outcomes weren’t just measures of business success—they translated into tangible user benefits. Employees could focus on innovation instead of administrative hurdles, new hires ramped up faster, and the company could adapt swiftly to external challenges.

A Day in the Life: Before vs. After Propel

Watch the demo below to see firsthand how life for a Breg engineer transformed after switching to Propel.

Before Propel: Navigating Breg’s systems felt like an obstacle course. Engineers spent up to two days searching for basic part information, jumping between multiple disconnected systems, and relying heavily on supply chain and quality teams for support. 

Critical data was often buried in PDFs or locked away in binders, requiring manual entry for analysis and creating inefficiencies that slowed everything down. This outdated workflow not only delayed decision-making but also frustrated employees, who spent more time battling systems than innovating.

After Propel: The transformation has been remarkable. Engineers can locate parts in minutes using a centralized, intuitive system that provides real-time data and cohesive collaboration. Accessing crucial information no longer requires tedious back-and-forths or manual workarounds. 

Employees feel empowered and independent, with the tools they need to make informed decisions readily at hand. The shift was more than operational; it fundamentally changed how work gets done, boosting morale and productivity across the board.

Lessons from Breg’s Journey

Breg’s story highlights the power of a well-planned digital transformation that is focused on delivering value to end users and the business itself. A “Big Bang” approach is intimidating—for good reason—but when done well, it will result in rewarding, demonstrable gains.

By prioritizing a user-centered approach, Breg ensured the new system worked for the people using it every day. Engaging end users throughout the design and implementation process not only created a better solution but also fostered widespread buy-in and enthusiasm for the change.

This clarity of purpose enabled them to advocate effectively for the changes and make decisions that stayed true to their goals. Their journey underscores that success in transformation is as much about having clear goals and the right team as it is about technology.

Here’s what other organizations can take away from Breg’s journey:

1. Go Big or Go Home: Incremental changes work great for many companies, but a comprehensive, interconnected system overhaul is best when existing processes cause too much pain for the incremental approach.
2. Put People First: Involve end users at every stage to design solutions that truly meet their needs. This is vital to delivering transformation that positively impacts employees and the bottom line.
3. Stay the Course: A clear vision and a relentless focus on ROI can overcome even the toughest resistance. Skeptics become believers when they see the end results.

Propel: The Catalyst for Transformation

Breg’s transformation highlights the extraordinary potential of Propel to not only streamline operations but to empower organizations to think bigger, act faster, and achieve more. 

By combining robust PLM and QMS capabilities with an intuitive, user-friendly platform, Propel enables companies like Breg to break free from legacy constraints and drive meaningful change. 

Breg’s story is proof that choosing the right technology can empower people to do their best work. When done right, transformation doesn’t just change processes; it changes what’s possible.

Dive into the full story behind Breg's 186% ROI. Download the case study by Nucleus Research to see how Propel made it possible.