Before you spend on a new line, it's worth finding out how much of your existing capacity is actually being used. We calculate true theoretical versus achieved capacity, balance the line against its slowest station, and build a debottlenecking plan — with an expansion roadmap ready for when you do need more.
What’s Included
- Theoretical vs. actual capacity study
- Line balancing
- Bottleneck identification
- Debottlenecking roadmap
- Expansion feasibility & cost estimate
- Capacity utilization dashboard
Our Process
Capacity Audit
Rated capacity is compared against actual output across shifts and SKUs.
Constraint Mapping
The true bottleneck station or resource is isolated from the noise.
Enhancement Plan
Options are ranked by cost and impact — from rebalancing to targeted capex.
Implementation & Validation
Changes are rolled out and re-measured against the original baseline.
Key Benefits
More output from existing assetsOften the fastest way to add capacity is removing what's blocking it.
Clear expansion roadmapWhen you do need a new line, the business case is already built.
Lower cost-per-unitFixed costs spread across a higher, steadier output.
Reduced lead timesBalanced lines mean fewer surprises in delivery commitments.
