Category Archive: Contract Kitting Services

Kitting Electrical Components

Kitting Electrical ComponentsPeoria Production Shop provides kitting services for various companies in the electrical industry. We recently partnered with WAGO, an electrical solutions company. According to the WAGO team, the company is projected to be number one in sales for the upcoming year.

PPS provides our electrical kitting services for WAGO. Currently, we kit Wago Wall-Nuts, or pushwire connectors. These products are not found anywhere else on the market. Typically, installation jobs require wires to be twisted, taped, or crimped. These wall-nuts, however, allow for easy installation by simply stripping the wire and pushing it in the wall-nut.

WAGO solutions save customers time and money. Also, they eliminate the hassle of contracting a professional for installation because anyone can use WAGO wall-nuts.

WAGO sends us the materials and quality guidelines for kitting. Our employees place the required quantity of wall-nuts and installation instructions into a clamshell. Then, the products are ready to be shipped to the original manufacturer.

PPS: Electrical Kitting Solutions for our Customers and Employees

Although the kitting order is not difficult, it allows us to provide a job to more individuals with disabilities, ultimately furthering our mission. Our goal is jobs, not profits, therefore we are always looking for ways to help our employees gain financial and social independence.

We are very fortunate to be partnering with WAGO, as providing kitting solutions to our customers provides opportunities for our employees. Our focus on this type of reciprocal, long-term relationship is what sets PPS apart from other suppliers, we succeed when you succeed.

One goal of PPS is to expand our business to connect with more companies in the electrical industry. We have the knowledge and equipment to deliver cost-efficient, contract kitting to manufacturers of all sizes with skilled, trained employees, ERP inventory tracking and meticulous attention to detail.

Peoria Production Shop provides value-added, kitting solutions to companies in need.  We focus on your total satisfaction to allow us to further our ultimate mission, employing individuals with disabilities.  Contact us to learn more about our high-quality, cost-efficient, electrical kitting solutions.

3 Reasons You Should Engage Kitting in Your Manufacturing

Kitting is a great way for manufacturers to save time and money as well as to optimize inventory management. Kitting is a value-added service that can benefit your company.

The process involves taking different individual components and combining them together to create a kit with a new SKU. By combining products, you can quickly and easily locate items when an order is placed which allows for companies to ship rather quickly.

If you believe your company can relate to any of the following reasons for kitting, you should consider kitting!

Kitting is Outside of Your Scope

It’s okay if you have no experience in kitting! At PPS, one of our main value-added services is kitting. Therefore, we are able to take on your project and guide you through the process. Our highly trained employees are experienced in kitting and knowledgeable about many niche markets. As a solutions provider, we take the stress off your backs. We succeed when you succeed.

We have many customers that hand us their product and ask for solutions. We are always happy to provide suggestions to make your product better in the end. Our alternative solutions help our customers to save money in the long run.

Looking to Save Money

There is no doubt that fulfilling orders is an expensive task. That’s why we want to help you save time and money with what we do best, provide cost-effective solutions for kitting and packing. By outsourcing your kitting, you save money during your production process by:

  • Eliminating search time for components – with all materials handy, workers save time and can operate most efficiently
  • Reducing packaging costs – consolidating items prior to packaging saves considerable packaging costs in baggies, dividers, corrugated boxes and labeling
  • Reducing labor costs – employees save time searching for items, in packaging and shipping when working with one box instead of several
  • Freeing up warehouse space – inventory is streamlined with each individual item having full traceability with a kitting provider who is ISO registered and uses ERP system lot code tracking.

Outsourcing kitting to an experienced, quality kitting provider saves considerable time and money for OEMs of all sizes with less materials required and less labor for more efficient production.

Wanting to Increase Efficiency

Every company knows time is money and strives to have the most efficient processes. Kitting services allow items to be processed in bulk rather than individually, saving manufacturers both time and money. Kitting also helps to track inventory as orders come in. If workers do not instantly know where a product is, that causes downtime and the overall productivity suffers. Pre-sorted kits save time and labor because those components are available and easily accessible whenever needed.

At Peoria Production Shop, we follow lean manufacturing practices. This means that we work to eliminate waste, optimize your processes, cut costs, and boost your efficiency. PPS strives to improve your bottom line and helps you remain competitive against other companies in your industry.

There are many reasons why you should consider incorporating kitting into your manufacturing processes. Whether or not you have knowledge about kitting, PPS is willing to provide the best solution for you. Request a quote for your kitting needs today.

 

Quality Operating Procedure

Quality Operating ProcedureWhat is a Quality Operating Procedure? (QOP)

A quality operating procedure (QOP) is a written document composed of step-by-step instructions used to complete a routine operational task. These procedures help to achieve efficiency, performance, and quality control.

Quality Operating Procedures are important to ensure that production operations are performed consistently to maintain the quality of products and processes.

The purpose of operational procedures is to define systems, assign responsibilities and authorities, and provide instructions for carrying out activities comprising the quality system. Operational procedures explain the what, when, who and how for each activity; identify interfaces for the activity; and instruct who should be informed and how the results of the activity should be recorded.

PPS uses specific coding for our operational procedures such as QOP-SS-NN. QOP stands for Quality Operational Procedure, SS is the section in the quality manual to which the procedure pertains, and NN is the consecutive number of a procedure for the section.

Importance of Quality Operating Procedures

1. Increases Business Productivity

QOPs can be beneficial for companies that produce the same product over a long period of time. PPS has been working with a Fortune 100 manufacturer for over 80 years. The procedures help to increase business productivity.

2.Processes Remain Consistent as the Company Expands

PPS is expanding so QOPs can make the work processes portable. Our new employees at the new location can uphold our reputation by using the same QOPs to replicate the products and services provided at the original location.

3.Reduces Errors

Standardized procedures help guide our employees and reduce the possibility of missed steps that impact the quality of the completed product. A QOP ensures that our customers’ products are created in the same way from start to finish every time, creating consistency with high-quality products.

4. Keeps Processes within the Company

Writing down procedures helps to keep key information with the company. This is beneficial when new employees take over a process and for cross-training of employees. It is important for the company to have a physical copy of all work instructions and procedures with documented alterations and continual improvements noted.

5. Better Time Management

QOPs are a valuable component for a new hire, ultimately reducing training time. As PPS expands, we will be hiring more employees. With specific work instructions, the quality operating procedure details the checks for quality personnel.

As an ISO registered company, we use Quality Operating Procedures to remain consistent when following strict quality guidelines. PPS promises to maintain the quality of our customers’ products. Visit our website to join our quality team.

 

In-Process Inspection Report

 

ISO certified companyPeoria Production Shop follows strict quality standards with processes in place to ensure an understanding of the process for high-quality results. As an ISO certified company, you can have confidence in our commitment to meeting your specifications.  We use in-process inspection reports (IPIR) to identify problems as they arise and immediately take corrective action. Our highly trained staff use these reports to streamline the inspection process and ensure work orders are completed accurately.

Prior to the inspection process, the supervisor is responsible for processing the work order and preparing the work station for the operator. During this step, the supervisor will fill out the specific information for the job on the IPIR such as the sales order, part number, quantity of order, package quantity per carton (bag or container), and specific work instructions to be used. The IPIR sheet stays with the product at all times.

After the workstation has been properly set up, the supervisor will inform the quality inspector of the job or new operator. This step can happen at any time of the work day as work orders are completed or operators are shifted around the facility.

The Inspection Process 

  1. Take IPIR Report and random sample of product from operator’s work area
  2. Check a minimum of 5-10 pieces (according to work instruction quality guidelines)
  3. Document findings on IPIR sheet
  4. Communicate those findings with operator
  5. If product is non-conforming, the quality inspector talks to the supervisor. A supervisor must sign off on the IPIR sheet before work can continue.
  6. Quality inspector repeats the process every 30 minutes.

Along with the IPIR sheet, the quality inspector carries a daily report sheet and a work instructions binder to each area that requires inspection. The quality inspector is solely responsible for identifying errors. The supervisor is in charge of correcting any issues with products or processes such as a machine or scale calibration.

The IPIR sheet helps the quality inspector to recognize any patterns. Since the in-process inspection sheet is used for the full duration of the work order, the quality inspector can draw conclusions about an operator’s ability to perform the task or the effectiveness of a machine.

At Peoria Production Shop, we strive to add value to every product we touch. Our quality team follows strict policies and procedures.  If we find that a particular employee is better suited to perform a different task than the one assigned, we place our workers where they excel and perform to the best of their abilities.  This policy has proven to be beneficial to ensure that we provide high-quality products, on-time and with consistency.

At PPS, we use in-process inspection reports and materials to aid in-process inspections  and to ensure finished products meet customer specifications. We promise to do our part and take appropriate action as needed so our customers can succeed. Visit our website to see how we can further your company’s success as a value-added, quality supplier.

 

Tool Kitting for Higher Education

Peoria Production Shop provides kitting services for various products and components. Our goal is jobs, not profits, which allows us to provide competitive solutions to our customers in many industries.

As an ISO 9001:2015 registered company, we follow strict quality standards to deliver contract kitting to manufacturers and OEMs of all sizes. Our full material traceability system and highly trained staff produce premium quality products based on customer kitting requirements.

Our modern facility has ample storage for the safety of raw materials and unfinished products. Specifically, we recently partnered with Bradley University, a local institution of higher education in Peoria, Illinois.

Kitting for Health Care Workers

Bradley University has a nationally ranked doctor of physical therapy degree. Students wishing to help people overcome physical impairments and injuries can pursue an undergraduate degree in health science and kinesiology or a doctorate of physical therapy. Bradley’s program provides students with preparedness for their professional practice. Students work closely with mentors in the classroom or clinicals.

The University promises a 100% employment placement rate with students working in the field within six months of graduation after completing the doctoral program.

With all of this great student success, we wanted to help make a difference in the lives of our future health care workers. We combined multiple products into physical therapy kits for Bradley University students complete with supplies to suit any patient’s needs. The kits include a multi-pocketed, heavy-duty medical bag, percussion reflex hammer, tuning fork, goniometer set, tape measure, luggage tag, and more.

In the future, we would love to continue to collaborate with higher education programs to provide kitting services. We have seen great success in the physical therapy students at Bradley University and want to continue to add value to more customers and industries.

Peoria Production Shop strives to make a difference in as many peoples’ lives as possible. We wish to support our local businesses through our contract assembly, kitting, sewing and other value-added services. Contact us to see how we can make an impact on your business and improve your supply chain.

ISO 9001 Kitting Process Diagram

This handy little kitting process diagram begins with demand and ends with shipment. Kitting is a perfect way to increase productivity in your organization. At Peoria Production Shop, we use proper steps to fulfill a kit and that process is tallied against a checklist. The checklist includes:

  1. demand
  2. sales order generation (work order)
  3. bill of materials (BOM) pull
  4. setup
  5. first article of inspection
  6. in-process inspection
  7. finally a last tally to meet sales order requirements

Peoria Production Shop is a ISO 9001:2015 registered company. We practice strict quality policies throughout our facility in all value-added services.

ISO 9001 Kitting Process Diagram

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ISO: 9001 Kitting Process

ISO: 9001 Kitting ProcessKitting is the process of combining multiple SKUs into one singular unit. Our management system accurately manages your inventory using full material traceability and inventory control processes.

The kitting process begins with demand and ends with shipment. At Peoria Production Shop, we use proper steps to fulfill a kit and that process is tallied against a checklist. The checklist includes demand, sales order generation (work order), bill of materials (BOM) pull, setup, first article of inspection, in-process inspection, and finally a last tally to meet sales order requirements.

Initial Sales Order After Demand

The customer creates the demand. Once we receive the demand, we work with the customer to coordinate a due date for the demand. Then, we will produce a sales order, which acts as a work order for the shop floor.

Order Reaches the Shop Floor

After the sales order reaches the floor it is accompanied with the BOM (bill of materials). The BOM lists the specific parts and quantity needed for each kit. Our inventory control system aids in the process of selecting products because it provides the employee with the exact amount of parts needed to pull for each kit. Then, an employee will go through our Scanco material tracking system and pull the product from locations on the BOM.

Labeling the Processes

Once products are selected, the employee begins setting up at a designated work table. The employee will put identifiers on the table that directly mirrors the BOM requirements. In other words, we write the part name and quantity of parts for the kit on a piece of “tape” that will be displayed on the table. This helps simplify the process for the operators because each part of the kitting process is labeled.

First Article of Inspection

A setup inspection is completed after the parts are pulled and correctly identified to the specific work table. We continually follow established work processes with strict quality control as part of our ISO9001:2015 standards and utilize an In-Process Inspection Report (IPIR) form. This is a controlled document, therefore, any revisions and changes are controlled through the quality procedure relating to the process of control of documents. The first article of inspection is done once the coordinator confirms the setup. This is a crucial step because it shows that setup was done correctly and the operator running the kit understands the processes.

Production Begins

After these processes are confirmed and documented as a pass then the production can commence.  Each kit that we run has quality guidelines paramount to the success and quality of a kit.  During the processing of a kit, no matter the size of production, all quality guidelines must be documented on the inspection form before the finalizing of a kit can be done.

Final Inspection

After the kit is completed it has to go through a final inspection process. In other words, we tally the kits and ensure that all of the quality guidelines were met. At this point, specific shipping instructions are identified.

Processing the Completed Sales Order

The sales order is then transferred to the office where it will be processed systematically within our Enterprise System Planning (ERP) SAGE system or through customer relations within our customer service department. The documents created are a pick sheet within our internal processes and a bill of lading for shipping.

Confirming Shipment and ISO9001:2015 Impact

A delivery or pickup is confirmed and the process is complete after a signed Bill Of Lading. Through ISO9001:2015 standards, we are able to assure the customer that we have done what we have said we would do from a Quality Operating Procedure (QOP) perspective. We follow strict quality standards and have validations in place to help with quality and understanding of the process. ISO9001:2015 provides added assurances over companies that do not have the certifications as it provides credibility to our business mission and goals. Also, it creates confidence in our customers that we have an infrastructure of processes that make us a great fit for kitting services.

Peoria Production Shop is a ISO 9001:2015 registered company. We practice strict quality policies throughout our facility in all value-added services. Visit our website to learn more about our kitting process.

Kit Assembly Services and Fulfillment

At Peoria Production Shop, we have contract packaging and fulfillment capabilities. Our highly trained staff and modern equipment provide customers with value-added services all while following strict quality processes.

What is Kitting?

Kitting is the combining of separate pieces into a single component. The kitting process makes it so products are ready-to-ship, saving an OEM time and money.

What is Fulfillment?

Fulfillment is all of the steps a company takes between receiving an order and placing that order in the customer’s hands. The process includes receiving and storing inventory, processing the order, and shipping the order.

Utilizing Kitting and Fulfillment

Many industries are taking advantage of companies that do both kitting and fulfillment services. Whether it’s toys, tool kits, gift baskets, subscription services–these businesses benefit immensely from a company that can do all of the capabilities under one roof.

Utilizing kitting and fulfillment helps to cut overhead costs. Also, due to the combining of products into one unit, items can be processed in a faster and more efficient manner. Kitting and fulfilling orders from one facility reduces shipping mistakes and errors.

PPS Kit Assembly Services and Fulfillment

At Peoria Production Shop, we partnered with DAGZ Dice Game to put their products together. The DAGZ game is a competitive and entertaining bar game that uses dice to mimic the premise of larger popular games such as horseshoes, corn hole and washers.

By combining multiple pieces into a single kit, toy companies can produce efficient order fulfillments. PPS stores the products at our facility and fulfills orders based on customer requirements.

We also work with subscription box companies. At PPS, we help companies increase their bottom line by saving them money on packaging and kitting. 

Kitting and fulfillment has proved to be a successful strategy for increasing profits and lowering operational costs. Want to optimize your supply chain? Visit our website to learn more about our value-added services.

Kitting and Assembly Solutions

Kitting and assembly services provide many benefits to original equipment manufacturers (OEMs) such as reducing internal assembly costs, improving quality, efficiency and profitability.

Kitting is a fulfillment process that involves the combining of multiple SKUs into one component.

 

What are the Key Benefits of Kitting?

      • Free Up Space
        • Moving inventory and kitting services to an outside firm allows for more floor space for production needs.
      • Reduce Cost of Labor and Improve Efficiency
        • Kitting saves time and labor by ensuring components are available by eliminating “search time”.
      • Control and Reduce Stock
        • Combining products allows inventory to be reduced, which ultimately leads to better material traceability and stock control.

Contract Assembly

Contract assembly is an approach where an original manufacturer hires an outside manufacturer to produce components determined by the original OEM’s specifications.

What are the Key Benefits of Contract Assembly? 

      • Higher quality products
        • Contract manufacturers have the tools and expertise to create exceptional products that might not have been available in-house such as automated assembly tools.
      • Reduced Costs
        • Contract manufacturers use advanced technology which means outsourcing contract assembly eliminates the need for original manufacturers to invest in manufacturing instruments. Likewise, the original manufacturers do not have to hire a large staff. Hiring a subcontractor allows for the company to reap the benefits of a large workforce without spending the extra funds on staffing.
      • Saving Resources
        • Contract assemblers use lean manufacturing to help reduce waste and add value to the proper processes.
      • Industry-specific solutions
        • Experienced contract manufacturers can provide knowledge for a niche industry. The contract manufacturer’s expertise of the industry can help to negotiate prices for bulk materials which can help reduce costs.

Peoria Production Shop has been providing solutions to original manufacturers needs for 80 years. We work closely with our customers to ensure projects are completed with efficient processes and attention to detail, providing a competitive value. Visit our website to learn how our kitting and assembly solutions add value to your project.

Does Product Kitting Reduce Dock-to-Stock Cycle Time?

dock-to-stock efficiencyA shipment arrives at the warehouse dock and needs to be stocked. The processes used between dock and stock are important and can make a real difference in warehouse efficiency. The better a business can become at efficiency and accuracy, the more profitable and successful it will be product kitting, might be the answer you’re looking for. .

What is Dock-to-Stock?

One of the most essential metrics is the “Dock-to-Stock” measurement. It helps to streamline the receiving process to get all items where they need to be as quickly and efficiently as possible. This allows warehouse receiving to move incoming materials quickly for faster cycle times to complete a finished product.

There are many variables that can affect operations. One major issue is that businesses tend not to focus their time and efforts on streamlining their processes.

The Benefits of Kitting

  1. Streamline Distribution

Kitting allows for an easier distribution of products as the items have been kitted in advance.

  1. Faster Assembly

When kitting is done in bulk, it becomes more of a linear operation, allowing for more items to be kitted in a more efficient manner. Likewise, the employee will not have to search for inventory as the products will be combined under one SKU.

  1. Fewer Shipping Mistakes

Shipping items in a kit form reduces the chances of error with order fulfillment. Likewise, it allows for pre-printed shipping labels which eliminates time to weigh products and any potential waste.

  1. Better Packaging

Combining multiple products into one kit saves on shipping costs with more efficient and cost-effective packaging.

All of these benefits of kitting can be translated into cost savings and overall more efficient for the dock-to-stock cycle time. Kitting allows for a “grab and go” process that is much quicker than individually searching for parts.

Using pre-assembled kits allows for projects to be fulfilled. Combining products allows us to better organize inventory and optimize warehouse space. Kitting makes it simpler to locate what is needed for an order, boosting the efficiency and productivity of the processes. Kitting products allows for a much faster fulfillment process, which ultimately reduces shipping delays that could happen if the items were packaged individually. Time can be translated to money. It is important to get the greatest amount of products fulfilled for the least amount of time and money.

Peoria Production Shop uses lean kitting processes to ensure our customers are receiving the most value. Kitting helps to speed up fulfillment processes for lower costs and less time. Contact us to learn more about how we reduce our dock-to-stock cycle time.