Kitting & Co-Packing Results: Rapid Scaling, Reliable Staffing.

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16 years

Partnership supporting kitting, co-packing, and retail display assembly
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98%

Fill Rate During Rapid Ramp
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0 → 200

Associates Scaled Within Two Weeks
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0

Safety Incidents in Over 5 Years

Partner Profile

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Our partner is a global leader in sustainable packaging solutions, including corrugated packaging and retail-ready display materials used by major consumer brands and retailers. The company supports high-volume display and endcap programs across retail, consumer products, beauty, home improvement, e-commerce, and industrial markets.

Capstone has supported this partner for 16 years, providing embedded kitting and secondary packaging support that helps the operation respond to changing customer needs without carrying unnecessary fixed labor costs.

The Challenge

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Retail display and endcap programs are highly variable by nature. Each new customer request can bring a different product mix, display design, build sequence, quality requirement, and labor profile.

Our partner needed skilled teams that could move quickly from quote to execution while maintaining consistency across safety, quality, efficiency, and staffing.

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Flexible Labor

Scale labor up or down based on changing project demand.
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Rapid Production Line Setup

Build and staff new production lines with minimal lead time.
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Complex Display Assembly

Support constantly changing display and endcap programs while maintaining quality standards.
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Skilled Workforce Management

Recruit, onboard, train, and coordinate operators, quality associates, material handlers, strappers, drivers, and packers on site.
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Our Approach

Capstone built the operation around a stable core team, embedded process expertise, and rapid labor scalability.
  • Keep an experienced core team in place to preserve site knowledge, maintain continuity, and provide a dependable base of talent.
  • Design each line around the work to define the production setup, establish clear standards, and create an effective labor plan.
  • Staff for the ramp, not just the plan, to protect fill rates and maintain continuity by planning beyond headcount requirements.
  • Manage each line for safety, quality, output, and staffing, using quality teams and software to track labor standards and time.

Our Solution

Capstone provides a flexible operating model for highly variable retail display work. The partner can match labor to demand, support new customer programs quickly, and execute complex kitting and display builds without carrying excess fixed labor between projects.

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Engineer Each Production Line

Capstone’s industrial engineering team sets up each line, establishes production standards, and creates the staffing plan based on the requirements of the specific build.
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Deploy the Right Skilled Labor

Within one week, Capstone can staff a production line with the right mix of cell operators, quality associates, strappers, material handlers, drivers, and packers.
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Scale with Demand

During surge periods, Capstone can move from a lean core team to a significantly larger workforce in a matter of days.
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Maintain Operational Control

Embedded leadership, quality support, labor management, and performance tracking help maintain safety, quality, efficiency, and staffing standards as project requirements change.
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