Tripling Throughput, 5× the Revenue on 20% More Headcount
Case studies
Healthcare claims Client anonymised Multi-year · ongoing

Tripling Throughput, 5× the Revenue on 20% More Headcount

A US firm in the high-volume healthcare claims-processing sector was turning away profitable work — its 1990s system and a 19–27-screen manual workflow had hit a physical ceiling. Two parallel tracks tripled throughput and grew revenue 5× on only ~20% more headcount.

~3×
Monthly throughput
Tripled — same team
5×
Revenue growth
On ~20% more headcount
30
FTEs' capacity freed
Year 1, via automation
60%
Routine work automated
Within months
Industry
Healthcare claims processing
Region
United States
Engagement
Full digital transformation
Started as
Competitive tender — API integration

The client operates in the high-volume healthcare claims-processing sector — high-value, high-sensitivity work where accuracy is not optional. When a sharp rise in market demand sent claim volumes surging, the opportunity was immense. The infrastructure to meet it was not.

Their core system was a homegrown, 1990s-era case-management tool. Processing a single claim meant navigating 19 to 27 separate screens, clicking and re-entering the same data at every step. The operation could only scale in one direction: more claims meant more people.

And the people had run out of room. The business model was linearly dependent on human labour, and the office had literally run out of desk space for the staff needed to keep up. The company was turning away profitable work because it couldn’t fit more keyboards in the building.

19–27
Screens per claim
~80%
Workload that was manual

The client came to us through a competitive tender with a narrow brief: connect their systems to external data sources. We won the work — and the diagnostic showed that a simple API pipe would solve almost nothing.

Roughly 80% of the daily workload was repetitive data entry and administrative click-work. Rather than spend years building the future platform while the backlog grew, we ran two tracks at once: automate the legacy mess now to free capacity immediately, and architect the cloud-native replacement in parallel.

  • Every automation had to clear one rule before we built it — it had to save at least half a full-time role. If we couldn’t prove the return, we didn’t build it.
  • A one-week break clause sat inside the R&D work, so the client could stop any path the moment it stopped making financial sense.
  • And when they asked for risky open-AI chatbots inside a regulated environment, we said no and explained why. Each call reduced their exposure, not ours.

Every metric moved, and they moved together. The same team — with only about 20% more headcount — processed roughly three times the claim volume. Automation absorbed the equivalent of 30 full-time roles: capacity the business would otherwise have paid for in salaries and desk space.

Revenue grew 5× from the year the engagement began. The second building was never rented. Growth had been capped by processing capacity; once that ceiling lifted, the business could close more work at the same margins — and the gain landed in the P&L, not in a bigger payroll.

The software mattered less than what it freed people to do. Staff who had spent their days clicking through screens moved to the work technology can’t touch — time with the client’s own customers, the judgment-heavy decisions. As the results landed, the brief widened on its own: the automation led to a platform rebuild, the rebuild earned security certification, and the certification led the client to ask us to help stand up an adjacent line of business. They already had a CTO to keep the technology running; what they’d been missing was the seat that bridges business strategy and execution. Today that seat is ours.

How we built it
Track 1 · Weeks, not months
Automation bots
We robotised the highest-volume manual steps with Python scripts and crawlers that bridged the external data sources and the legacy system. Within months they were handling roughly 60% of routine intake and data entry — removing the re-keying burden before the new platform was even finished.
Track 2 · The permanent fix
Cloud-native platform
In parallel we built a modular, serverless platform to replace the legacy monolith: portals for case handlers and admins, a client-facing portal that let customers track cases in real time (a differentiator no competitor offered), and automated payment and admin reconciliation.
Track 3 · Ongoing
Document AI layer
A closed, compliance-first AI layer (AWS Bedrock, Titan, Claude) reads unstructured PDFs and supporting records, extracts the fields that matter, and surfaces them to specialists — moving people from data entry toward judgment. It already helped the client stand up an adjacent service line in weeks, with humans making every decision.

Trust in a partnership like this isn’t given — it’s earned, decision by decision. We challenged the brief before writing a line of code, said no when no was the right answer, and proved the return before spending their money. That’s what turns a one-off integration into a true partner relationship.

Cezary Bielecki
Cezary Bielecki
CEO & Founder, Digital Forms
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