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Case Studies

Read our case studies on a selection of projects and get a deeper insight into our competencies and methodology.

Capacity Increase: API Manufacturing

Capacity of 4 API lines increased by >15% following 9 month roll out of standardized improvement structures ....

Capacity Increase: Batch Monomer Production

Increasing the capacity of a batch monomer production by 32% in 7 months....

Working Capital Reduction: Protective Textiles

Reducing working capital via stock reduction by $10M and a new S&OP Process....

Reducing Order Backlog: Automotive Paints

47% increase in batch releases within 1 month of starting project....

CapEx Avoidance: Polymer Production Capacity

Increasing the capacity of two main production lines by >20% and >50% led to a significant (>€15 million) CapEx avoidance....

Working Capital Reduction: Breakfast Cereals

Releasing over £1M cash through stock reduction in a breakfast cereal production company....

Output Increase and Meeting Delivery Targets: API Manufacturing

Capacity of high-urgency API increased by ~50% in <20 weeks. Cycle time improvements of another product enabled the agreed customer delivery date to be met.....

Increasing Productivity and Yield: Sausage Production

Increasing productivity by >20% and reducing waste by >20% in 6 months....

CapEx Avoidance: Soft Drinks Packaging

In two days, opportunities identified to increase capacity of bottleneck processes by > 15% and > 20%, avoiding €500k+ CapEx....

On Time, In Full: DIY & Homeware

OTIF failures reduced by > 85% within 8 weeks of project start....

Improving Yield: Pharmaceuticals

Improved batch yield to increase plant throughput rate by 64% in three months....

Increasing Output: Energy Metering

Output increased by > 70% and scrap costs reduced by > 50% in 9 months....

Increasing Output: Foil Wrapped Perishables

Output increased by > 100% in 4 months to match surge in customer demand....

Cost Reduction: Synthetic Fibres

Labour efficiency increased by >25% across multiple departments in 12 months, saving millions of euros per year....

New Process Development: Juice Drinks

New test methods developed, enabling raw material giveaway losses to be reduced by >£1m in 6 months....

Working Capital Reduction: Liquid Consumer Products

> £1M in working capital and £500k+ in overtime and temp labour costs recovered in 3 months....

New Product Development: Lead Time Reduction

>75% reduction in new product development time to market vs historical NPD timescales following 3 month project....

Cost Of Sales: Metal Waste Containers

Productivity increased by > 30% across multiple departments within three months ....

New Process Integration: Lead Time Reduction

Solved new process technical issues to increase manufacturing efficiency by > 40% in 4 months....

Capacity Increase: Wind Turbines

Causes of scrap and rework eliminated to increase output by 25% and reduce resin yield loss by >70% in 3 months....

Cost Reduction and Lead Time Reduction: Defence Services

> £1M reduction in yearly engineering costs and > 35% reduction in refit time delivered in 12 months....

Technical Services: Training Courses Delivery

Opportunities identified to improve the efficiency of training delivery - reducing required trainer and delegate time by > 35%....

Increasing Capacity: API Cycle Time Reduction

> 25% increase in line capacity demonstrated, following a 5 month project across multiple key assets....

Improving Output and Yield: Intraocular Lenses

Yield of intraocular lenses increased by > 40% in 3-months. End-of-year output targets hit in Q1.....

Capacity Increase: Whey By-Product Production

Increased the capacity of a whey by-product manufacturing process by 31% in 3 months....

Increasing Capacity: Specialist Adhesive

Increased capacity of a specialist adhesive product by 22% in 9 months....

Capacity Increase: Specialist Chemical Resin

Increasing the capacity of a continuous resin manufacturing process by > 40% in 6 months....

Productivity Increase: Spray Drying

Increased Productivity across 6 Production-Constrained Spray Dryers by 39% in 8 months....

Capacity and Productivity Increase: Medical Packaging

Increased capacity of medical packaging production line by >35% in 4 months....

Increasing Capacity: Blood Plasma Processing

Increased output of a production-constrained blood plasma processing facility by > 80% in 18 months....

Capacity Increase: Sterile Injectables

Chartwell has run several projects to increase output of sterile injectable products....

Learn more about what we do:

What We Do

We embed ourselves in your team to help your business achieve more than you believe is possible.

Methodology

Find out what differentiates Chartwell's approach from organisation-wide change programs such as Six-Sigma and Lean.

Training

Join us at CATCH - we will be running hands on problem solving training in a real life factory setting.

Graduates

Find out more about how to apply.

Case Studies

Search By Project Type

Search By Industry

See Full List

Search By Project Type

Search By Industry

See Full List

Case Studies

Read our case studies on a selection of projects and get a deeper insight into our competencies and methodology.

Capacity Increase: API Manufacturing

read more >

Capacity Increase: Batch Monomer Production

read more >

Working Capital Reduction: Protective Textiles

read more >

Reducing Order Backlog: Automotive Paints

read more >

CapEx Avoidance: Polymer Production Capacity

read more >

Working Capital Reduction: Breakfast Cereals

read more >

Output Increase and Meeting Delivery Targets: API Manufacturing

read more >

Increasing Productivity and Yield: Sausage Production

read more >

CapEx Avoidance: Soft Drinks Packaging

read more >

On Time, In Full: DIY & Homeware

read more >

Improving Yield: Pharmaceuticals

read more >

Increasing Output: Energy Metering

read more >

Increasing Output: Foil Wrapped Perishables

read more >

Cost Reduction: Synthetic Fibres

read more >

New Process Development: Juice Drinks

read more >

Working Capital Reduction: Liquid Consumer Products

read more >

New Product Development: Lead Time Reduction

read more >

Cost Of Sales: Metal Waste Containers

read more >

New Process Integration: Lead Time Reduction

read more >

Capacity Increase: Wind Turbines

read more >

Cost Reduction and Lead Time Reduction: Defence Services

read more >

Technical Services: Training Courses Delivery

read more >

Increasing Capacity: API Cycle Time Reduction

read more >

Improving Output and Yield: Intraocular Lenses

read more >

Capacity Increase: Whey By-Product Production

read more >

Increasing Capacity: Specialist Adhesive

read more >

Capacity Increase: Specialist Chemical Resin

read more >

Productivity Increase: Spray Drying

read more >

Capacity and Productivity Increase: Medical Packaging

read more >

Increasing Capacity: Blood Plasma Processing

read more >

Capacity Increase: Sterile Injectables

read more >

Learn more about what we do:

What We Do

Methodology

Training

Graduates