Increasing chunk size or overlap is a band-aid that creates new problems (larger context windows, diluted embeddings).
The production fix is implementing hierarchical summarization:
This captures relationships that span chunks without bloating individual chunk sizes. Key implementation detail: Use UMAP before clustering to reduce embedding dimensions - set n_neighbors=10 for local structure (detailed clusters) or n_neighbors=sqrt(N) for global structure (broad themes). RAPTOR showed 20-30% improvement in answering multi-hop questions compared to flat retrieval.