Kitting

Definition

Kitting is a logistics process where various individual components or products are assembled into pre-configured sets or packages before being delivered to production lines or shipped to customers. This method optimizes material flow, reduces handling effort, and improves efficiency in production and distribution.

Process and Implementation

The kitting process begins with defining bills of materials for different kit variants based on production requirements or customer needs. Dedicated kitting areas are equipped with ergonomic workstations and optimized material flow systems.

Pick-by-light or pick-by-voice systems guide employees through the assembly process and minimize error sources. Quality controls validate kit completeness before forwarding to downstream processes.

Automated kitting systems use robotics for repetitive assembly tasks. Vision systems automatically verify kit completeness and correctness.

Production and Logistics Benefits

• Efficiency Enhancement: Pre-configured kits reduce search times and material handling at workstations by up to 40%
• Error Reduction: Central assembly minimizes picking errors and improves production quality
• Space Optimization: Compact kits require less storage space and simplify transport
• Flexibility: Rapid adaptation of different kit variants to changing production requirements
• Cost Savings: Reduced handling costs and optimized personnel deployment planning

Applications

Automotive Industry: Assembly lines receive pre-configured kits with all required components for specific vehicle variants. Just-in-sequence kitting synchronizes material provision with production takt.

Electronics Manufacturing: PCB assembly lines use kits with exactly needed components for different product variants. Component kits reduce setup times and material waste.

E-Commerce and Retail: Subscription boxes and product bundles are efficiently assembled through kitting processes. Seasonal or themed kits increase customer satisfaction.

Medical Technology: Sterilized instrument kits for surgical procedures ensure complete equipment and significantly reduce OR preparation times.

Kitting Strategies

Build-to-Stock Kitting: Standard kits are produced to stock for frequently requested combinations. Inventory management optimizes stock management of different kit variants.

Build-to-Order Kitting: Customer-specific kits are assembled after order receipt. Mass customization enables individual product configurations.

Line-Side Kitting: Kits are provided directly beside production lines for minimal transport distances. Kanban systems control demand-driven kit replenishment.

Technological Support

Warehouse Management Systems (WMS) orchestrate kitting processes and optimize workflows. RFID technology enables automatic kit identification and tracking.

Augmented reality systems visually guide employees through complex assembly processes. Digital picking supports error-free commissioning.

Machine learning analyzes kit demand for optimized inventory planning and production control.

Quality Management

Standardized work instructions define exact kit assembly and quality criteria. Four-eyes principle or automated controls validate kit completeness.

Error analysis identifies causes for kit deviations and leads to process improvements. Continuous improvement optimizes kitting efficiency continuously.

Integration with Production Systems

Manufacturing Execution Systems (MES) synchronize kitting planning with production orders. Real-time communication enables dynamic adaptation to production changes.

ERP integration ensures precise material requirements planning and cost tracking for kit components.

Future Trends

Collaborative robots (cobots) take over repetitive kitting tasks and work safely alongside humans. AI-controlled optimization automatically adapts kit assemblies to changing requirements.

Digital twins simulate kitting processes for optimal workplace design and workflow design.

Kitting evolves into a strategic instrument for lean manufacturing and agile supply chains that simultaneously optimizes material efficiency, quality, and customer satisfaction.