Boost your manufacturing capacity and drive business growth. Our high-performance operations consultancy increases productivity, providing swift, tangible and far-reaching efficiency improvements, based on your unique requirements through our capacity increase services.
Unblock the bottleneck
Hitting capacity is a common constraint for many manufacturers. But without the need for capital investment, we empower your team to optimize existing equipment and enhance processes for a more efficient and sustainable solution.
Our highly flexible methodology and tailored approach allows us to improve capacity regardless of sector or site. This enables companies to meet market demands and growth plans, while also helping you stay ahead of competitors.
Projects usually range from 10-12 week sprints through to 6-12 month broader implementation programs, with support structures in place for ongoing client improvement beyond Chartwell’s deployment.
Blending insight and instinct
To deliver rapid, remarkable, and long-lasting productivity gains, we combine a proven process with our time-served expertise and embedded team of engineers, scientists and specialists. Alongside technically and tactically identifying opportunities, our project management experience allows us to make fundamental changes to your organization in a matter of weeks to deliver on your capacity increase goals.
2 weeks
We quickly assess the scale of opportunity in your business – working closely with your team to understand the existing barriers and limits to performance through an Opportunity Scan.
2-3 months
As part of a pilot project, we will demonstrate just how much potential exists. We deeply embed ourselves into your workforce, forming a small team with a cross-section of your organization.
2-9 months
Using our results-focused methodology, we redefine possible to deliver remarkable results that impact the bottom line. Often seen in a matter of weeks, these tangible and far-reaching improvements will be based on your unique needs, and our team will support the wider organization through the change process.
Beyond Chartwell
By achieving sustainable results and implementing impactful solutions, our interventions are designed to remain effective long after the project or deployment is complete. But much of this depends on your team, and their ability to contribute to lasting improvement. As a result, we have developed a series of tailored workshops, toolkits and methodologies, which help you learn our approach, overcome constraints, and deliver improvements without us being on site.
Projects Include:
- Changeover reduction
- Line target speed increase
- Batch cycle time reduction
- Labor productivity
- Runtime efficiency
- Planned outage compression
FAQ’s
Explore frequently asked questions for Chartwell’s capacity increase solutions.
Increasing capacity with Chartwell
A capacity increase project at Chartwell removes the constraints that are limiting output, so you can produce more using your existing assets. Chartwell focuses on the bottleneck first, then scales improvements across the system to deliver rapid, measurable throughput gains without relying on major capital investment.
By optimizing existing equipment and strengthening the processes and routines that govern performance. That means removing bottlenecks, improving runtime efficiency, reducing changeovers, and lifting labor productivity so output rises sustainably without needing to buy new lines.
From our experience, capacity is usually constrained by one (or a small number of) limiting steps. Often driven by downtime, slow cycle times, changeovers, quality issues, unstable operating conditions, or poor visibility of daily losses. Chartwell’s first job is to pinpoint the true constraint and quantify the opportunity. This is done through our Chartwell Opportunity Scan.
Yes. Chartwell’s methodology is designed to improve capacity regardless of sector or site, tailoring the work to your process realities whether they are continuous, batch, discrete, or hybrid operations.
Results depend on the constraint and starting point, but Chartwell increases capacity to deliver swift, tangible improvements and consistently improves manufacturing productivity by 20–50% within 6 months.
The work is designed to remain effective beyond deployment by establishing practical performance routines, visibility tools, and coaching so the team can hold the gains and keep improving. Chartwell also offers workshops and toolkits to build capability.
What a Chartwell capacity increase project looks like
Chartwell’s delivery is typically phased: ~2 weeks to assess as part of the Chartwell Opportunity Scan, 2–3 months to demonstrate results via a pilot, and 2–9 months to redefine performance at scale depending on your scope and needs.
Chartwell rapidly assesses the scale of opportunity by working closely with your team to identify the barriers and limits to performance as part of the Chartwell Opportunity Scan, so you get a clear view of the constraint, the losses, why opportunity exists and the fastest path to results.
Chartwell demonstrates what’s possible by embedding into the workforce and forming a small cross-functional rapid results team (RRT). The RRT prove the gains in live operations so the wider rollout is grounded in real results, not theory.
Using a results‑focused methodology, Chartwell delivers tangible improvements, often seen in weeks, and supports the wider organization through the change process.
The intent is the opposite: improve performance while production continues. The team works in the reality of day-to-day operations, implementing changes in a controlled way so improvements are delivered without unnecessary disruption. This is vital as we are often supporting our clients with the their most urgent challenges, and therefore need to manage continued customer delivery as well as significant change.
A committed cross-functional core team and access to operational data and daily realities. Sustainable improvement depends on your team’s ability to adopt routines and drive the changes forward. Chartwell builds that capability as part of our improvement projects.