@Flashman:
I solved two of the problems listed above in one swoop by using a completely different chip system:
Each power has just one stack of units in a tt:
white - 10 infantry
grey - infantry
red - artillery
dark blue - fighter
brown - tank
By mixing in all the chips from all my A&A games I just have enough. Some of the stacks are rather tall, but overall there’s much less messing about swopping chips and shifting stacks, and there’s no overcrowding on the western front; hence, less chance of knocking over stacks.
The artillery, tank and fighter sculpts are now redundant, but the game is a lot more manageable without them.
note: Harry Larris is the chap I interviewed about the game, he is not me.
Have you considered just painting some stripes down the side of the chips? Black for armor, red for artillery ect…. Red on red would be 5 art, black on white would be 1 tank.