Category Archive: Contract Kitting Services

Outsourcing EV Cable Assembly

Cable AssemblyElectric Vehicles (EVs) continue to be a growing industry and topic of discussion, especially as gas prices only go up and eco-friendly solutions are mandated due to climate change. EV cable harnesses have many components that require precision assembly.

Some stripping and crimping of cables can be done with automated equipment, while other tasks require manual work and assembly. Working with high-voltage connectors requires specific work processes to be performed in order. Automated processes cannot be used for every task, and some manual requirements are more complex than others.

Benefits of Outsourcing EV Cable Assembly

Some EV cable types require a certain set of processing steps, while others require different steps to be followed. In some cases, it could make sense for the manufacturer to automate critical steps and outsource other processes, such as assembly. There are many benefits to outsourcing various aspects of EV assembly requirements. A manufacturer’s decision to outsource is dependent upon various factors, and evaluation of the potential benefits will help to decide the best way to meet manufacturing goals.

Reduces Labor Expenses

One of the biggest advantages of outsourcing electric assembly processes is the reduction of labor expenses, which is not just limited to wages. Companies can avoid the need to hire staff, invest in training, and provide benefits, taxes, and insurance. Outsourcing also allows companies to meet their production and shipping demands without worrying about maintaining the proper staff levels throughout the year, even with fluctuations in production requirements.

A contract electronics kitting provider will be there when you need them, and you don’t pay for their services when they are not needed. This helps reduce labor costs and helps companies to grow by focusing on their most important needs without worrying about staff levels for electronic kitting and assembly projects.

Improved Efficiencies

EV producers are continually investing in research and development and product improvement. Outsourcing electronic assembly processes allow companies to focus on improved manufacturing techniques and efficient production. By outsourcing electronic assembly services, companies can rely on their contract assembly provider without the need to invest in automated equipment and workstations optimized for the efficient flow of goods.

Changes in Production Demand Are Met Quickly

When production demands change quickly, an outsourced provider is always ready without the need to invest in new staff, training, and capacity for increased production and assembly requirements.

Experienced Electronics Kitting Services

Peoria Production Solutions, PPS, is an industry-leading contract electronics kitting services provider with more than 80 years of experience in helping companies to meet production goals. We offer custom kitting and assembly, including contract electronic kit assembly, electronics kitting services, sub-assembly, final assembly, single or multi-step assembly, and assembly of various mechanical and electrical components.

PPS provides peace of mind to companies that require careful electronic kitting and assembly with a track record of satisfied customers. We substantially invest in our employee training and development programs with a focus on meticulous attention to detail. PPS offers automated equipment, a large, modern facility, and a staff dedicated to a job well done and total customer satisfaction.

PPS differs from other contract electronic assembly providers with our not-for-profit status, allowing us the flexibility to provide solutions that other assembly providers cannot. We utilize automated equipment combined with a skilled and trained workforce to deliver quality assembled products, on time. Contact us with any questions and for cost-efficient, high-quality solutions for your next electronic kit and assembly requirements.

Auto Poly Bagging Fastener Kits

Poly Bagging Fastener Kits

 

Auto bagging hardware pieces like fasteners, nuts, and bolts, with other necessary materials, is a popular custom kitting technique. Polybagging fastener kits saves time for field personnel to have the right parts ready when needed or provides a convenient package for the end-user. 

Fastener Kits Save Time with Convenience

Fastener kits put together for specific tasks such as assembling furniture or for specific repairs such as computer repairs or kits containing skateboard hardware, for example, give the buyer everything they need in one convenient, protected pouch. Polybagging hardware and fastener kits is also a common practice during manufacturing processes where operators require specific parts during their assembly application. Fastener kits can be provided along with products during a manufacturing process and sometimes sold on their own for specific processes, such as a picture hanging kit. 

Designing Custom Poly Bagging Fastener Kits

Auto poly bagging processes are used in many applications for retail, commercial, and industrial applications to protect specific merchandise required for production, shipping, or sale. Identification tags can be attached to poly bags to indicate the number of products included, with barcode labels for tracking purposes. This one SKU can replace the numerous individual SKUs of all parts included, improving inventory movement applications. 

Designing a poly bagging process requires careful consideration of a few important factors:

  • The specific products included in the bag
  • The number of products to be auto bagged
  • The type of poly bag or pouch most beneficial for packaging

Determining the exact products to be included is one of the most obvious important decisions to make when designing an auto-bagging process. Fasteners can be included with other required hardware or products, such as plastic parts or adhesives. Printed materials can also be included, such as an inventory list of kit contents and assembly instructions.

The quantity of custom poly bagged products is a critical decision to ensure all required parts are included in possibly a couple of extra fasteners or nuts and bolts if some get lost or damaged. Companies also must ensure they have adequate inventory to maintain custom bagging processes to support product ordering and sales.

The type of packaging is another critical decision, as there are several different types of poly bags available in different sizes, shapes, weights, and thicknesses.  The type of packaging chosen should protect the parts inside for proper bagging and sealing, with the most efficient material available without jeopardizing product or process quality. 

Types of Poly Bags for Custom Auto Bagging and Kitting

There are several types of poly bags available for custom auto-bagging processes, which requires careful consideration of certain factors to choose the best type. Companies will want to consider the size of the bag required, the bag’s physical characteristics, and costs. Some bags will be visible to consumers, others will simply be used for protective packaging during shipping. 

The most common types of poly bags include polyethylene and polypropylene types of bags, with many different variations of polyethylene density.

High-density polyethylene, HDPE – HDPE bags are less flexible and denser than other types of polyethylene bags providing excellent resistance to tears and punctures. HDPE bags are often used to package heavy items such as construction material, sand, and cement, but can also be useful for packaging bulk food items and irregularly shaped products with sharp edges that could poke a hole in other types of bags.

Low-density polyethylene, LDPE – LDPE bags are less dense than HDPE bags providing more flexibility and clarity to see products on the inside. LDPE bags tear easier than other types of bags, which is convenient for products that require easy access, lightweight, and have visibility, such as for small parts or temporary storage.

Linear low-density polyethylene, LLDPE – LLDPE bags provide higher tensile strength and puncture resistance than LDPE bags without jeopardizing flexibility.  LLDPE bags can save money with thinner gauge material and still provide strength, making them common for grocery store use, where clarity is not an issue. 

Medium-density polyethylene, MDPE – MDPE is not quite as dense as HDPE, although it still provides heavy-duty properties with resistance to stress and cracking. MDPE bags are useful to protect against external damage, debris, and moisture. 

Polypropylene, PP – PP bags are the second most common type of bags used compared to polyethylene bags and are growing in popularity due to high tensile strength and clear visibility. Polypropylene provides increased resistance to heat and chemicals over polyethylene. 

These are some of the most common types of bags used for auto-bagging processes, although consulting with an experienced custom kitting and auto bagging provider will help you determine the right type of materials for your process.

Peoria Production Solutions, PPS, offers more than 80 years of experience as a contract packaging provider, offering all types of packaging services, including auto bagging. We utilize modern auto bagging equipment, heat sealers, heat tunnels, band sealers, hot stamp imprinters, and other auto bagging technology combined with a skilled, trained staff. Contact us to learn how to improve your poly bagging application with an experienced, quality-minded auto bagging provider. 

Custom Kit Assembly & Gift Set Packaging Provider

Custom kit assembly is the process of combining two or more individual products into one assembled kit with one single SKU. Custom kitting and gift set packaging are ideal for companies to prepare similar items for retail sales. Kitting can improve packaging and shipping time and reduce overall expenses.

Common Gift Set and Custom Kit Assembly Products

Custom kitting can be used in a wide range of markets to fulfill many types of orders. Some of the most common types of products that are commonly grouped together for custom kitting or gift set packaging include cosmetic kits, skincare kits, toys, entertainment media, product samples, and many other types of items.

Oftentimes, purchasing kitted items is a better value than buying items individually. This is a good way for companies to boost their sales while still providing cost savings to consumers.

Cosmetic Kits

Cosmetics are commonly packaged with like items that appeal to consumers, such as eyeshadows, mascara, and eyeliner grouped together for a complete eye makeup kit. Shades of eye shadows and blush colors that go together or foundations and powders in the same color scheme are commonly kitted for consumer convenience. Cosmetic companies often introduce new products in a custom kit and may offer more promotional items in gift sets during the holidays.

Skincare Product Kits

Skincare products are also commonly kitted together with facial cleansers, moisturizers, and toners that work together to provide a full skincare regimen. Skincare items can be grouped together based on skin types, such as dry skin or oily skin. Kitting is a very popular sales approach for many companies in the skincare industry to help keep costs down and cater to consumer needs.

Toys

Custom kitting and gift set packaging has been a common practice in the toy industry for a wide variety of toys such as model cars and airplanes, Lego kits, Barbie dolls and clothing accessories, Nerf guns, coloring books with stickers or other activities, outdoor games, and more. Toys, games, and hobby kits grouped together provide cost savings for the manufacturer and convenience for consumers.

Entertainment and Media Kits

The entertainment industry is another popular market for kitting, or companies can offer discounts for purchasing a series of movies or books that go together. Media systems like sound bars and speakers, televisions and mounting brackets, or car stereos and speakers are other options for kitting that can improve company sales and provide savings to buyers.

New Product Samples

Kitting services are a popular way for companies to promote new products, and offering product sample kits gives customers a chance to try the product out before buying a full-size version. Companies in all types of industries promote new products with kitting for a cost-effective way to increase brand awareness. A sampling of several types of products is often quite appealing to consumers, such as a variety of lotions or perfumes.

Gift Set Packaging

Gift set packaging is extremely popular around the holidays with everything from cosmetics, pajama sets, tool sets, cooking ware, holiday decorations and more packaged in a convenient gift set. Gift set packaging is not just for the holidays, however, with clothing and personal care items often available in gift sets for convenient bundling or gift-giving any time of the year.

With the many opportunities for kitting and gift set packaging, companies need a contract packager with experience in kitting and assembly to help them navigate the many options.

Kitting, Assembly, and Gift Set Packager

Peoria Production Solutions, PPS, has been providing contract packaging services for more than 80 years and offers extensive experience in all types of kitting and assembly. PPS is an industry-leading Midwest kitting and assembly provider, offering secondary production solutions, including packaging, repackaging, and gift set packaging.

PPS offers secondary production solutions to a wide range of businesses and industries, helping some of the largest Fortune 100 companies meet their production goals. We offer the resources, staff, and capacity to dedicate kitting and assembly lines for your process, with a controlled flow of goods, ERP product traceability, and ISO9001:2015 quality policies. Contact us to learn more about improving your kitting, assembly, and gift set packaging process.

Optimizing Your Assembly Through Kitting

Contract Kitting ServicesKitting supports assembly and production processes in the warehouse or on the manufacturing line. Kitting is an excellent logistics strategy that involves grouping together individual parts or components with individual SKUs into one package or kit with one SKU. The kit includes all items needed at a particular assembly or manufacturing station where operators have everything they need to assemble or contribute to final product production.

Kitting in a warehouse for assembly significantly improves lean processes as workers do not need to search and find necessary components to support their process. A kitting strategy improves lean processes and reduces errors at the same time. When workers have everything they need in a kit that has already passed inspection, they know these parts are the correct items and meet quality standards.

Assembly lines are common in many manufacturing segments such as automotive, aerospace, medical components, appliances, furniture, and more. Grouping products together for smooth operation only makes sense to keep these processes on task with a streamlined flow of goods. Kits that support these manufacturing processes are sequenced to move along the assembly line as required were numerous components that could not be marketed separately or joined with other processes to form a final product or contribute to the manufacturing process.

Outsourced Kitting Provides Many Advantages

Kitting provides many advantages with a streamlined flow of goods and supports lean manufacturing and production operations. Performing kitting in-house, however, poses many challenges for companies. Businesses that wish to incorporate kitting in their process to reap the many benefits with improved flow of goods must first determine the products to be kitted, and set up an internal kitting station that requires capacity and labor.

Outsourcing kitting to a contract kitting and assembly provider alleviates these challenges and provides additional benefits to companies. Contract kitting service providers already have the capacity and systems in place to perform reliable, kitting and assembly of products received. This allows companies to focus on their area of expertise and niche manufacturing, warehousing, or retail operations.

Some of the most important advantages of outsourcing kitting include:

  • Reduced movement and optimized work time

  • – when assembly workers do not have to gather and prepare items for their station, the reduction of movement and time to look for materials optimizes productivity.

  • Eliminates errors
  • – workers that receive kits already assembled can have confidence in having the right parts at the right time that have already passed quality inspections. This eliminates human error in picking incorrect products and ensures quality assemblies.

  • Increased productivity
  • – kits delivered to the right station at the right time with the right products significantly boost productivity to ensure uninterrupted, continuous assembly.

  • Maximizes capacity
  • – companies that outsource kitting maximize facility capacity without the need to dedicate workstations just for kitting. Space can be allocated strictly to necessary assembly and production without wasting valuable resources on a subprocess.

PPS Offers Contract Kitting and Assembly with Value Added Services

Peoria Production Solutions, PPS, supports a variety of warehousing and manufacturing operations with experience in kitting and assembly services. We offer more than 80 years of expertise in meticulously assembling kits for a variety of market segments. Our modern, state-of-the-art facility provides ample capacity to dedicate workstations for high quality and controlled kitting. We offer a variety of value added services to meet specific customer requests, such as sewing, various packaging solutions, wrapping, palletizing, and shipping.

Our Enterprise Resource Planning, ERP, system provides tight quality control with full accountability of all customer-supplied material and lot code traceability. We practice strict quality policies with top-down involvement, and invest in our skilled and dedicated staff with ongoing training and cross-training programs. PPS practices lean operations and Value Stream Mapping, VSM, exercises to ensure the most efficient kitting and assembly to support timely delivery of quality products.

PPS is recognized as a leading kitting and assembly provider, offering solutions to a wide range of industries and applications. We partner with our customers to provide customized kitting solutions that meet your needs and exceed your expectations. Contact us to learn more about optimizing your process with an experienced contract kitting provider.

Kitting in Automotive Manufacturing

Automotive Parts KittingKitting is the process of combining related items together, taking multiple SKUs, and creating one SKU in one kit. Kitting products is common practice in many retail market segments but kitting also provides many benefits in a manufacturing environment. Kitting tools together for easier usage in the manufacturing process supports lean production processes with everything operators need at the assembly or production stage.

Determine Which Automotive Tools to Kit Together

Kitting tools for automotive applications is similar to how a mechanic keeps his toolbox. Everything that is needed for a certain process is organized and readily available. Automotive manufacturers need to determine the exact tools on hand, where they are located, and where they are needed. Do these tools need to travel to other departments? Should they stay at one particular workstation? Which tools should be used together, and what are the storage capacities?

Specific work instructions should document kitting and production procedures at each stage of the manufacturing process.

Kitting for Quick and Accurate Assembly

The most important reason for kitting in automotive is to support just-in-time manufacturing with kits of materials delivered to the right location at the right time for maximum efficiency. This is also called offline kitting. When manufacturers determine the exact components required for kitting, outsourcing to a contract kitting and assembly provider can even further optimize the process for lean production.

Outsource Kitting to Optimize Automotive Manufacturing

Kitting is an inventory management technique that supports faster production and assembly lines with lean storage and streamlined processes. Once automotive manufacturers determine the exact tools and components that should be kitted, outsourcing kitting to a contract kitting and assembly provider provides many benefits.

Manufacturers that receive fully stocked kits of all of the parts needed can direct them to the proper location quickly, without allocating floor space and labor to perform the kitting in-house. This saves on labor expenses and allows manufacturers to focus on their niche product production. Partnering with an experienced contract kitting and assembly provider provides even more benefits with in-depth expertise in kitting and packaging techniques.

PPS Offers Kitting and Assembly for Automotive Tools and Components

Peoria Production Solutions, PPS, is an experienced contract kitting and assembly provider, offering solutions to companies of all sizes, including automotive manufacturers. We offer more than 80 years of experience in performing contract kitting, assembly, packaging, and other secondary production services, allowing us to enhance our customers’ productivity and profitability with quality products delivered on time.

PPS has the capacity in our large, modern facility to set up dedicated workstations to ensure quality and timely kitting and assembly. We follow strict quality policies aligned with our ISO9001:2015 certification and enjoy a dedicated workforce committed to performing high quality, meticulous work to exceed customer expectations. With decades of experience and continual investment into the latest technology to support automated processes, we are experienced in kitting with various types of packaging such as in tool boxes, foam holders, secondary and flexible packaging, wrapping, and palletizing.

PPS offers kitting solutions for companies of all sizes and applications, such as for order fulfillment, warehousing, manufacturing, and various market segments, such as automotive, medical applications, consumer goods, and more.

PPS is recognized as a leading production solutions provider with vast experience in secondary production services, including kitting, assembly, sewing, packaging, repackaging, palletizing, and more. We ensure high quality work with a skilled staff and tight quality control with automation tools such as our ERP system. Contact us to learn more about improving your automotive process with kitting and assembly from an experienced contract kitting provider.

Hand Assembly & Kitting Outsourcing in Lean Manufacturing

Outsourcing for Lean Manufacturing

Companies practicing lean manufacturing experience many benefits with improved process efficiencies, inventory management, lead times, and profitability. Assembly and kitting are practices that contribute to lean production operations when designed and implemented properly. Hand assembly and kitting can be labor-intensive and monotonous for manufacturers.

Outsourcing assembly and kitting can improve your own lean operations, and when contract kitting suppliers practice lean operations, you can have confidence in receiving quality products on time.

Identify Waste in Lean Production

Lean principles and practices can be applied to any industrial process with the main focus on eliminating waste in production. Identifying inefficiencies and waste is key to implementing lean practices and improvements. Hand assembly operations can introduce various inefficiencies with intricate, time-consuming tasks that can create bottlenecks in your process.

The 8 Wastes of Lean, as identified by SixSigma.us, follow the acronym TIMWOODS and include:

  • Transportation
  • Inventory
  • Motion
  • Waiting
  • Overproduction
  • Over-Processing
  • Defects
  • Skills

All of these areas should be evaluated when identifying inefficiencies or waste in hand assembly and kitting.

Critical Steps to Lean Hand Assembly and Kitting

Careful evaluation of these areas will help contract kitting and assembly providers to eliminate waste with lean hand assembly processes.

Transportation – the distance required to transport work in process from one department to another is a key area of improvement. Simple production compositions with the shortest transportation distance available promote lean operations.

Inventory – assembly and kitting providers that maintain enough inventory for the process without creating excessive over stocking situations are most efficient. Inventory is an asset, although excess inventory is considered wasteful.

Motion – unnecessary movement required of employees, machinery, or equipment is wasteful. When workers need to stretch, reach, lift, walk, or bend in excess, these extra movements add up to wasted minutes and hours and could create repetitive stress on personnel. Reducing motion waste improves efficiencies and increases employee health and safety.

Waiting – when employees are waiting on material or equipment that is sitting idle, this waiting halts production and disrupts efficient assembly and kitting. Designing processes to ensure continuous flow prevents unpredictable bottlenecks.

Overproduction – producing products with the “just in case” theory instead of “just in time” may keep an idol workforce busy, but overproduction creates excess inventory that is wasteful. Lean assembly and kitting follow the rules of lean manufacturing, where products should be produced to order, not prior to demand.

Over-Processing – overprocessing includes performing added functions over requirements. Companies that utilize a Kanban system experience benefits from an effective tool that supports smooth running production and highlights lead times and cycle times for improvement.

Defects – recognizing a defect in an assembled component after assembly is extremely wasteful and requires disassembly of the entire unit. Every workstation and every kitting and assembly process should display clearly defined work instructions, including any critical dimensions that should be checked and images of common defects. All employees in every stage of the assembly process should be performing visual inspections or taking measurements as required.

Skills – not utilizing the human talent and ingenuity present in employees is a waste of skill. Companies that engage employees in the process allow for improvements.

PPS Practices Lean Assembly and Kitting

Peoria Production Solutions, PPS, is an ISO9001:2015 certified contract assembly and kitting provider, following a strict quality policy with top-down involvement and employee engagement. We support lean production for some of the largest Fortune 100 companies in the country, as well as small to medium-sized businesses. PPS helps companies of all sizes to improve lean operations with reliable, high-quality contract kitting and assembly services.

Our Enterprise Resource Planning (ERP) system provides complete traceability and full accountability of all customer-supplied material. We practice Value Stream Mapping to improve process efficiencies and eliminate bottlenecks for a streamlined workflow. Cross-training of a skilled work staff improves efficient product flow, supporting lean assembly and kitting practices.

PPS is recognized as a lean assembly and kitting provider with more than 80 years of experience, automated equipment, and a skilled work staff. We have the capacity to set up dedicated assembly workstations, allowing you to free up capacity to focus on your niche manufacturing process. Contact us to learn more about our lean practices and how we can add value to your supply chain with lean hand assembly and kitting services.

Kitting & Assembly: Learn the Difference and the Benefits

Benefits of Kitting & Assembly

Kitting and assembly are two terms that are often used interchangeably, although they actually refer to different processes. Kitting and assembly are used to improve efficiency in manufacturing or to package pre assembled products for consumer convenience.

What Is the Difference between Kitting and Assembly?

When determining the best production or fulfillment solution for your operation, you may want to evaluate the efficiencies that kitting and/or assembly can provide and learn the difference between the two.

Kitting

Kitting is a process that bundles two or more items together to create one single, ready-to-ship, or ready-to-use kit with a new single SKU. Kitting products together helps manufacturers when several components are required during a manufacturing process to have all the tools and materials needed at the right place and time to facilitate efficiency. Kitting helps inventory tracking by compiling all components into one new SKU to simplify inventory management.

Kitting is also used to satisfy end-user consumer needs with several components sold together as one kit. Many examples of this include subscription boxes, cosmetics, hardware, and direct mail kits, the list is endless.

Assembly

Assembly is a process that involves combining two or more separate components together to create one product that is then sold or used as a single item. Assembly lines are used in many fulfillment centers when products must be assembled in bulk. Assembly lines are common in production facilities and provide efficiency to manufacturers for mass production of various components from small items all the way up to automobiles.

Kitting and Assembly: In-House Or Outsourced Process?

Both kitting and assembly are processes that are commonly performed in-house, at the place of fulfillment or manufacture. Many companies, however, are realizing the benefits of outsourcing kitting & assembly to experienced providers.

Kitting and Assembly In-House

Companies that perform kitting and assembly as part of their own production process must allocate resources to support the in-house process or sub-process. Resources include the space to perform kitting and assembly processes, employees to perform the kitting which involves training and labor expense, and time allocated to manage the inventory and logistics of all products.

Kitting and Assembly Outsourced

Companies that outsource kitting and assembly processes can realize significant benefits when evaluating the process thoroughly and putting a cost to the time and effort of in-house operation and management. When production lines can simply pack parts in bulk and ship to a kitting provider, rather than take up their own floorspace to combine their own parts into a single unit, they can allocate that space to other production processes. This helps to grow their business and focus on their niche product market.

Partner with a Kitting and Assembly Provider

When evaluating kitting and assembly providers, look for a company with experience, attention to detail, capacity, a proven quality track record, and the willingness to partner with you for ongoing success. Peoria Production Solutions, PPS, has been providing kitting and assembly services for more than 80 years. With a large, state-of-the-art facility featuring 17 shipping and receiving bays, we have the capacity to dedicate kitting and assembly workstations to ensure an optimized flow of material.

PPS is committed to total customer satisfaction by investing in our staff with ongoing training and development and a focus on high-quality work processes. We enjoy extremely low turnover, and a dedicated team committed to providing efficient, quality production solutions with meticulous attention to detail. We provide kitting and assembly solutions for companies of all sizes, including some of the largest manufacturers in the country.

PPS offers high-quality kitting and assembly with decades of experience and a commitment to excellence. We practice lean operations, cross training, value stream mapping, full product traceability, and ISO:9001 certified processes. Contact us to learn more about improving your efficiencies by outsourcing kitting and assembly to a quality-minded, experienced kitting and assembly company.

How Material Kitting Enhances Manufacturing

Material Kitting

Manufacturers often kit final products to bundle items together for sale to consumers but kitting also plays a beneficial role in the manufacturing process.

What Is Material Kitting in Manufacturing?

Manufacturers are focused on the most cost-efficient production to produce quality products, with a focus on continual improvement, reducing waste, and streamlining processes. Kitting materials that are required during a production process can significantly improve production cycle times and shop floor efficiency. When certain jobs require specific tools, materials, and work instructions and the required kits are available where and when they are needed, this significantly cuts down on operator time hunting down all the materials required.

Kitting may include certain raw materials that go into a particular product, packaging materials for that product line, or labeling materials. Quality control inspection checklists combined with the equipment necessary for specific jobs could be kitted to improve efficiency during QC inspections and ensure that all required parameters or critical dimensions will be checked as required. Material kitting in manufacturing can significantly improve production times by ensuring that all materials, parts, or components that are required during a process are available when needed.

When to Use Material Kitting

When considering incorporating or changing a material kitting process in your manufacturing application, there are some situations where kitting adds significant value. If the following conditions exist, you might want to evaluate your material kitting process:

  • When a large variety of small components are required to be incorporated into the production process
  • When time is being wasted locating materials and components on the production floor
  • When some products require customization of things like shape, color, accessories, or packaging
  • If there is a shortage of space that prevents stocking required materials closer to the area needed on the production line
  • Material kitting can enhance the production process if any of these situations exist or other conditions which can be improved with streamlined methods.

    How to Use Material Kitting in Manufacturing

    As manufacturers create the Bill of Material or BOM, for specific production jobs, everything that is a part of that finished product, including all materials and labor, is accounted for. When components in the BOM arrive at the production process when and where they are needed, in a ready-to-use kit, operators save time for improved efficiency.

    All of these individual components can be kitted to create a new SKU, which simplifies inventory and handling. Quality is also improved with a kit of parts that have already passed all quality control measures and are assured to be within acceptable specifications. Kitting requires production managers to determine the most beneficial products and materials to bundle for improved manufacturing efficiency.

    When kitting multiple components in large quantities, it may be beneficial to utilize the services of a contract kitting and assembly provider.

    PPS Provides Material Kitting for Manufacturing

    Peoria Production Solutions, PPS, offers kitting solutions to manufacturers of all sizes, including some of the largest Fortune 100 manufacturers in the country. We utilize our large, modern, state-of-the-art facility with the capacity to dedicate kitting stations designed to meet customer specifications. With a dedicated staff, automated equipment, and a commitment to detail and quality processes, PPS improves production efficiencies in a variety of industries and markets.

    We are experienced in efficient kitting processes, practicing lean operations including value stream mapping (VSM), to improve efficiencies and reduce waste. PPS offers a variety of secondary production solutions such as kitting, assembly, packaging, and many secondary packaging solutions customized for the manufacturing line or display-ready products.

    PPS is an industry-leading production solutions provider with more than 80 years of experience. We differ from other kitting providers in our kitting expertise and commitment to our staff and customers. Contact us to learn more about improving your material kitting to enhance your production processes.

    Improving Assembly Efficiency with Kitting

    mproving Assembly Efficiency by Kitting	 parts

    Efficiency is a key driver of profitability, especially in manufacturing operations where time is money. Kitting is proven to improve efficiency, thus increasing profitability, in many manufacturing applications. Having the parts required delivered to a certain production station at the time they are needed saves operators from hunting for parts that they need and supports lean, continual production operations.

    Kitting Saves Time, Time is Money

    The cost of each component produced, whether a small part or a large automobile, is dependent upon a few different factors, including the raw materials going into the product, the cost of labor, and the time it takes to produce each unit. Reducing the “cycle time” of each product produced is one area where manufacturers have some control and try to improve, thus reducing each component’s cost. If time is shaved even in seconds off of a production cycle, that’s seconds that are opened up to produce more parts. Time reductions also provide more production for the same labor expenses in most cases, thus making labor more efficient.

    Lean Manufacturing with Kitting

    Reducing time where possible is one key aspect of lean manufacturing. Reducing the time it takes to produce products and the time that parts are stored in inventory, whether raw materials or finished goods, improves efficient operations. This is especially true in assembly operations where a production line must have the parts they need, as shutting down a major assembly line is not an option in many operations. Just shutting down one production line at an automotive OEM plant can cost tens of thousands of dollars in a matter of hours.

    Kitting Improves Efficiency and Inventory Reductions

    Storing products costs money in terms of taking up space in addition to the cost of the purchase. This is why many manufacturers practice lean manufacturing, which emphasizes waste reduction and optimized flow of goods, usually with just-in-time (JIT) deliveries of required materials. This also helps to prevent items from becoming obsolete while in storage.

    By reducing the amount of inventory, companies can improve their inventory turnover ratio, which indicates efficient inventory management, improving balance sheet ratios and cash flow. Kitting is an excellent way to improve efficiency when assembling components and to help reduce product cycle times and inventory storage. Kitting requires careful planning and logistics considerations to receive the right parts at the right time but is well worth the improvement in efficiency when assembling components.

    PPS Supports Lean Manufacturing with Kitting for Assembly

    Peoria Production Solutions, PPS, understands the importance of lean manufacturing and on-time delivery as an ISO9001:2015 registered kitting provider with more than 80 years of experience. We provide kitting solutions for companies of all sizes, including some of the largest Fortune 100 companies in the U.S., as well as small to midsize businesses.

    We practice value stream mapping (VSM) in our own operations to optimize kitting and assembly processes. This ensures the most efficient process to meet your production requirements with a focus on high quality and timely delivery. Our staff is unique in that we enjoy a dedicated team that enjoys coming to work and enjoys working together thus cross training, and fulfilling lean production processes are simpler when all team members are focused on providing an exceptional material flow.

    PPS utilizes automated equipment combined with a trained, skilled staff in addition to quality control and lean manufacturing best practices. We offer a large, modern facility with the capacity to dedicate customized kitting and assembly stations to meet customer needs. Contact us to learn more about improving your assembly operations from an ISO9001:2015 certified kitting and assembly provider.

    Advantages of Kitting Realized in All Market Segments

    Kitting is a process that provides solutions to a wide range of industries and sectors that rely on kits to streamline their manufacturing and fulfillment processes. Companies in many industries use kitting to improve internal operations or to satisfy customer demands.

    Advantages of Kitting Realized in Endless Industries

    Kitting can be found in such a wide range of industries and applications we simply cannot list them all, although some of the most common examples of how kitting benefits companies can be found in the following industries:

  • Automotive – automotive manufacturers rely on maintenance kits ready when they need them to conduct maintenance or repairs, service engines, transmissions, and critical components. Kits with easy access to the tools and parts needed significantly improve maintenance and production efficiency. Kitting provides organizational benefits to streamline a variety of automotive production processes.
  • Aerospace – Kitting helps to improve strict quality control and high-stakes industries like aerospace and aeronautics. Kits with parts that have passed quality control and are ready when needed support efficiency and safety.
  • Defense – military and defense operations rely on a broad range of kits with tools, mission-specific products, and equipment packages ready when needed.
  • Oil and gas – the oil and gas market utilizes kits containing repair and replacement parts, seals, sealing compounds, and critical components to support safe and efficient processes in the field.
  • Medical devices – manufacturers of medical devices require kitting when different devices are required to be assembled for the end user, whether for a hospital supply room, operating room, or customized to a specific patient.
  • Furniture and appliances, light fixtures – kitting provides solutions for various furniture and appliance and light fixture products. Combining products for replacement parts or custom lighting solutions improves branding and customer satisfaction.
  • Paper Goods, Sales, and marketing – kitting large quantities of paper products for brochures, sales and marketing, promotional materials, training programs, and more can be time-consuming for large companies to perform in-house. Third-party, contract kitting companies have been providing solutions for paper goods and marketing materials for decades.
  • Toys – kitting is a huge part of the toy industry, where many products must be organized and sold as a set. Many toys are packaged together in ready-to-ship kits, such as Lego products, model airplanes, board games, Barbie accessories, and more. Toy companies improve internal efficiencies and reduce errors when multiple elements are combined into a single kit to speed up the picking, packing, and shipping process with accuracy.
  • We often take for granted the kitting that is involved in the many products that we purchase. Making sure that consumers have what they need when they need them and having everything packaged for convenience and appeal is always on the mind of the manufacturer or the brand. When companies work with an experienced contract kitting and assembly provider, they can realize many benefits internally and with improved customer satisfaction.

    PPS: Delivering Decades of Kitting and Assembly Services

    Peoria Production Solutions, PPS, has been a leader in providing kitting and assembly services for more than 80 years. We offer high-quality, cost-efficient kitting solutions to companies in all industries of all sizes. We offer vast experience in a wide range of kitting products from small to midsize companies to some of the largest Fortune 100 OEMs in the country.

    PPS differs from other kitting providers in our commitment to employees, dedicated staff, and low turnover. As a fully sustainable not-for-profit organization, we offer the flexibility to customize your kitting and assembly requirements to meet your production and budgetary needs. Our focus is on providing sustainable employment to our staff rather than profit and on continual improvement with training programs and strict quality policies.

    PPS is a leading Midwest supplier of secondary production solutions, including kitting assembly, packaging, electronic kitting, and more. We utilize automated equipment, a skilled trained staff and adhere to strict quality procedures as an ISO9001:2015 certified kitting provider. Contact us to learn how to improve your kitting processes with an experienced contract kitting and assembly provider.