Production capacity optimisation is the process of ensuring that a plant or operation can produce the required volume and mix of products at the right time, without excessive investment or overtime. Consultants start by mapping current capacity (equipment, labour, shifts, changeover times) and comparing it with forecast demand to identify constraints and underused assets. They then apply tools such as line balancing, setup-time reduction, preventive maintenance, sequencing and, where justified, targeted capex to remove the true bottlenecks. The aim is to increase throughput and reliability before spending on large expansions, and to make output more responsive to demand swings. This is particularly valuable in sectors with seasonal peaks, multi-SKU portfolios or tight delivery promises. Done well, capacity optimisation raises overall productivity, reduces unit costs and strengthens the operation’s ability to support growth.
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Production Capacity Optimisation: What it actually means?
