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Tips to Maximize Kitting and Assembly

Tips to Maximize Kitting and Assembly Feature
Last Modified: October 24, 2019
Strategies to maximize kitting and assembly can be troublesome without the right resources, but developing an efficient system can simplify distribution process. These procedures are common in fulfillment and distribution warehouses because they save manufacturers time and money. In fact, kitting is
Fulfillment And Distribution
October 14, 2019
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Strategies to maximize kitting and assembly can be troublesome without the right resources, but developing an efficient system can simplify distribution process. These procedures are common in fulfillment and distribution warehouses because they save manufacturers time and money. In fact, kitting is a critical aspect of the supply chain. A variety of products, ranging from subscription boxes to electronics benefit from kitting and assembly practices

To maximize kitting and assembly, you’ll need to follow a strategy to optimize the kitting process in warehouses for maximum flow. To enhance your process aim to reduce bottlenecks, come up with standard procedures and use an organized warehousing partner. 

How Does Kitting and Assembly Work?How Does Kitting Assembly Work

Although kitting and assembly processes can be time-consuming for warehouse employees, the method overall is fairly simple. Kitting refers to the task of putting individual components together to form a single product. As an example, your iPhone likely arrived in a box with the phone, earbuds, a power block, and a cord.  Kitting would be the process of putting all these items in the box. 

Kitting is sometimes called product building. Assembly is the actual act of putting products together in the kit. These two tasks work hand in hand, your iPhone box contained multiple items assembled together and shipped as a kit.

Products that frequently require kitting and assembly services include:

  • Subscription boxes
  • Bath and beauty products
  • Cosmetics
  • Promotional items and media kits
  • Kits for multi-level marketing promotion
  • Product samples
  • Electronics

There are various methods for the warehouse kitting processes, such as packed-to-order sets, subscription boxes, and assembled products. 

Packed-to-order Sets 

An example of packaged kitting, packed-to-order sets save time and money for the distribution center. Many online shops rely on this kitting process as a marketing strategy. For example, if you’re purchasing a single coffee mug, it is oftentimes more expensive than the cost of purchasing a pack of four. This is the result of packed-to-order sets, less time is spent packaging the product and the companies are distributing more of its specified product.

Subscription Boxes

In today’s digital age, subscription boxes have become increasingly popular. Subscription services are usually made of many products and the boxes are not prepackaged. Regardless of your service allowing customization or shipped as a standard package, it is assembled under product kitting. This sometimes also includes another method of kitting and assembly known as pick and pack. The picking process allows warehouse employees to pick through a setlist of about ten items to prepare unique boxes with roughly 5 products in each subscription box. 

Assembled Products 

Several products offer made-to-order items where customers specialize in order to be shipped to them. If you purchase a laptop, each piece inside the packaging including the instructions, user guide, charging cords, the pc, and other elements were pieced together through kitting. 

If you are part of a business that needs kitting and assembly services, benefits to outsourcing this process are easily recognized. 

Benefits of Kitting and AssemblyBenefits of Kitting and Assembly

The process of kitting and assembly is a multi-tasking job, usually offered by third-party logistics companies (3PL). Like most order fulfillment processes, kitting and assembly processes keep warehouse workers busy, they must sort through and pack a plethora of items essentially forming a kit. Their efforts certainly aren’t wasted, as kitting can be a cost-effective solution for customers and manufacturers. The kitting process in the warehouse comes with many benefits.

Five benefits of kitting with an effective strategy include:

  1. Reduced and eliminated handling 
  2. Faster order fulfillment times as products can be pre-kitted from multiple Stock Keeping Units into a single SKU, simplifying tracking 
  3. Maximized usage of technology from warehouse management software
  4. Reduced waste from invalid kitting and errors
  5. Cost-efficient and cost-effective packaging for reduced shipping expense

Accuracy is essential when it comes to product assembly and kitting services. Utilizing the latest warehouse management system software to keep accurate counts of on-hand inventory and avoid error. This kind of inventory management can ensure all items are available before the kitting process begins. Being precise helps to avoid problems like:

  • Not enough or too many kit components
  • Incorrect or wrong components
  • Incomplete product kits


Tips to Maximize Kitting and Assembly

There are numerous ways to maximize the kitting and assembly process. Pre-packaging and pre-assembly are essential. Other ways you can get the most out of kitting and assembly include:

  • Reducing bottlenecks: Kitting and assembly processes should be designed with flow in mind. Your strategy should prevent bottlenecks and inefficiencies.
  • Establishing procedures: It’s wise to thoughtfully plan out your processes and procedures. This can help you maintain accuracy throughout product assembly operations.
  • Use an organized warehouse: When looking for a facility that participates in kitting and assembly, ask about the warehouse design. Choose a warehouse that takes advantage of clear signage and has designated picking areas.
  • Know the team: Manual kitting teams should always work at a consistent pace, preventing bottlenecks. Additionally, teams should take occasional breaks from kitting and assembly processes to regroup and reorganize.
  • Don’t assemble on-demand: Assembling your kits on-demand can slow down fulfillment and distribution. Assembling kits in advance makes things move quicker. It can also reduce the number of SKUs in the warehouse.
  • Check and double-check: It is wise to include a spot checkpoint in the kitting and assembly process. This can affirm accuracy and quality.
  • Come up with a plan: Ideally, all kits will make it to their destination as they were intended. In case of error, a back-up plan should be in place for correcting mistakes.  
  • Make plans for pre-packaging: Consider making product kits in advance. This can help businesses accommodate surges in demand and offer quick shipping.
  • Help reduce assembly time: Make your kitting and assembly process as efficient as possible to help reduce assembly times. You can do this by assembling a large number of kits at once instead of on-demand.
  • Ask for help from suppliers: If multiple items in your kit come from the same supplier, ask if they can be bundled together for shipment.


Kitting and Assembly Warehouses with R+L Global Logistics

Even with these tips to maximize kitting and assembly in mind, you’ll find it can be a complicated process. There’s more to kitting and assembly than simply putting items in a box. Kitted products should resonate with consumers.

You’ll find that a skilled kitting and assembly provider like R+L Global Logistics can create ready to ship kits that work for your customers. Our fulfillment and distribution workers are detail-oriented, allowing them to assemble kits accurately and quickly. 

The process to maximize kitting and assembly can be cost-efficient for all parties, kitting your goods together can reduce your per-unit costs. Kitting and assembly services are convenient, but the process can be complicated with an unorganized warehouse. R+L Global Logistics can help you maximize kitting and assembly and be your proactive partner helping to avoid all errors. Contact us today at 866-989-3082 to get started with kitting and assembly.


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