Category Archive: Contract Kitting Services

Selecting the Right 3PL for Your Kitting Needs

outsourcing kitting Many consumers appreciate the convenience of ordering products that go together in an assembled kit.  This is true for many types of products and for things that consumers buy regularly, they can order things as a subscription that is delivered at determined intervals. Products that are sold kitted, or assembled, or as a subscription service are often handled by a Third-Party Logistics (3PL) company. This includes a variety of products such as personal care items, food and beverages, technology items or clothing.

Retail businesses and manufacturers often find great value in outsourcing kitting and assembly to third-party logistics companies.  Some 3PL companies perform additional assembly processes as well as keeping track of inventory and shipping, although contract kitting companies can play a big role in helping 3PL companies meet their production and shipping demands.

What Is Kitting and Assembly? 

Kitting and assembly is big business for retailers and e-commerce companies to meet specific consumer demands. Kitting is the process of combining related goods together into a grouping that creates a new SKU, ready for shipment.  Various products are grouped for kitting such as subscription boxes, tool or hardware kits, first-aid kits, cosmetics, and more.

Contract assembly is the process of taking various products and assembling them together such as mechanical assembly operations, single or multiple step assemblies, assembly with complete packaging ready for shipping and customized, specific assembly procedures that create a final end product. Whether an e-commerce company or a 3PL provider, working with an experienced contract kitting and assembly company can provide many benefits.

Benefits of Outsourcing Kitting and Assembly 

Outsourcing kitting and assembly procedures to an experienced contract kitting company can provide many benefits that increase productivity and profitability. An experienced contract kitting company has the resources in place to perform these processes efficiently and timely. Contract assembly companies utilize sophisticated software programs to keep track of all incoming material for full traceability and accountability.

With plenty of capacity to set up customized assembly stations and a staff trained in performing high-quality kitting and assembly processes, contract assembly companies help e-commerce and 3PL businesses meet demanding shipping requirements.

How to Select the Right Company to Outsource Kitting and Assembly 

There are several things you should look for when selecting a company to outsource your kitting and assembly processes. Some of the most important considerations include:

      • Experience – the company should have experience in kitting and assembly with references, current or past comparable projects.
      • Resources – an experienced kitting company should already have the facility with capacity, the people, and the processes in place to meet your needs.
      • Inventory management – strict management of customer supplied materials with full traceability and inventory control is a must when outsourcing product kitting or assembly. Ask about the type of system used and whether or not they have ERP capability. Most companies today will use barcode traceability with the ability to scan products anywhere in the supply chain.
      • Quality control – what type of quality processes does the company follow and are they registered to standards like ISO9001:2015? Ask if they create specific work instructions for your process and how they can ensure those are followed?
      • Lead time – what is the company’s history with on-time delivery and how can they ensure meeting your production demands?
      • Packaging experience and flexibility – does the company have the resources to efficiently package all finished products and ship to your specifications?

Peoria Production Solutions, PPS, provides all these capabilities and more, with over 80 years of experience in meeting contract kitting and assembly requirements. We are an ISO9001:2015 registered company, with a large, modern facility, automated equipment, inventory control with ERP full product traceability and a skilled staff.

PPS is a leading Midwest contract kitting and assembly company, providing production solutions to companies of all sizes including Fortune 100 companies. We provide experienced kitting and assembly solutions with a trained staff and automated equipment. Contact us to learn how to increase your productivity and add value with cost-efficient, contract kitting and assembly services to meet all your 3PL needs.

 

Top 5 Myths Of Outsourcing Kitting and Packaging

Kitting and Packaging Myth ImageOutsourcing your kitting, assembly, or packaging processes may seem like a foreign idea with a lot of unknowns.  For small to medium sized companies particularly, those who have invested in staff, inventory, and training to sort, assemble and package their products, it may seem like a large task to start outsourcing this part of your business. The truth is, once you speak with an experienced kitting and packaging company, you may wonder why you didn’t outsource years ago.

Debunking the Top 5 Myths About Outsourcing Kitting and Packaging 

Businesses spend a lot of time developing their products, with efficient production methods and quality control. When it comes to packaging for inventory or sale, this is one area that requires just as much attention but can unfortunately be an afterthought.  Most companies and manufacturers are experts at what they do, the same goes for kitting and packaging companies.

By outsourcing to an experienced contract packager, you can actually improve your productivity and profitability by focusing on what you do best.  Here are some of the top 5 myths that may prevent some companies from realizing the many benefits of outsourcing:

Myth #1: Outsourcing is not worth the hassle 

It may seem like a giant task to pack up your products and ship to a skilled kitting and packager, although with the help of experienced contract packagers, this can be streamlined and simple.  Peoria Production Solutions has been streamlining kitting and packaging processes for companies for more than 80 years. We can show you how you still have complete control of your inventory even when not on your premises.  PPS keeps meticulous track of all customer supplied material with lot code traceability and strict quality control measures.  Once this task is relieved from your in-house processes, you realize just how much time is opened up to focus on your niche market. This, to us, is no hassle at all, just smart business.

Myth #2: Outsourcing is only for large companies, not small to medium sized businesses. 

We hope you realize the myth in that statement immediately. Nothing could be further from the truth as small to mid sized enterprises (SMEs) play a major role in the economy and help to drive innovation.  SMEs focusing on producing their goods or providing their services greatly benefit by outsourcing kitting and packaging to continue to grow their business with a trusted packaging partner on their team.  In fact, we might go so far as to say that outsourcing can help the SME as a bridge that allows you to grow your business and take your company to the next level. 

Myth #3: My customers won’t like us outsourcing. 

An experienced contract packager like PPS can have your products kitted, assembled, and shipped back to your plant without anyone knowing.  In fact, you will have more products ready to ship sooner, your customers will be nothing but happy.  As an ISO9001:2015 registered company, PPS takes pride in efficient operations and on-time delivery.  We can package your products discreetly and to your specifications.  We also specialize in creating display ready, secondary packaging, You receive your products fully assembled and ready to stock the shelves.

Myth #4: My kitting, assembly, or packaging operation is too complicated to outsource. 

A seasoned kitting and packaging company has seen it all, from numerous bags of small parts to keep track of, organize and assemble to display ready packaging.  PPS offers more than 80 years of experience in kitting, assembling, and packaging your goods to your exact specifications, no matter how many parts or components.  We can offer suggestions to improve your packaging with the most cost-efficient solutions available.

Myth #5: Outsourcing Kitting Is Too Expensive 

When considering the total cost to perform kitting, assembly and specialized packaging in house, most companies realize a cost savings by outsourcing. Consider not only the labor and cost of materials for your process, but the space and capacity that could be used for your production instead. Time and space both have value, be sure to optimize yours to the fullest.

Speak with an experienced contract kitting and packaging company at Peoria Production Solutions. We provide solutions to help you meet your production needs with high quality kitting, assembly, and packaging delivered on time.

Peoria Production Solutions offers contract assembly, kitting, and packaging from a skilled and experienced workforce. We offer more than 80 years of experience in meeting companies’ specific production needs. Contact us to learn more about the many benefits of outsourcing your secondary operations such as kitting, assembly, and packaging.

 

 

Great Packaging Includes Great Kitting and Assembly

Kitting and Assembly of subscription boxesIt really does not matter what you are selling, great packaging is important for businesses and consumers. Manufacturers rely on sturdy packaging to protect their products during storage or shipping. Consumers expect packaging that protects the products until they receive them and so much more.

Packaging today must be sturdy and protective, with marketing that appeals to consumers in clean and attractive bags, boxes, or assembled kits. To be competitive in today’s eco-friendly environment, companies must also use packaging that reduces waste and contributes to their corporate and social responsibility. In addition to these considerations, companies selling assembled kits need efficient packaging solutions that aligns with their goals to:

      • Protect products
      • Meet marketing demands
      • Produce minimum waste
      • Cost effective assembly

Companies that address all of these considerations are more likely to experience brand success and consumer loyalty. Companies must ask themselves today how to deliver their products with appealing wrapping or gift packaging, with recyclable materials, and at the lowest possible cost. Answers to these questions provide a good foundation for the right kitting and assembly services to meet your business model for profitability and consumer satisfaction.

Consider Cost-Efficient Pre-Assembly for Kitting 

Companies selling various products that require kitting such as cosmetics, tools and hardware, arts and crafts, and any other combination of products grouped together require an efficient method of kitting and assembly. Take a makeup kit for example, while many products must be assembled into appealing gift packaging, several of those products may require individual wrappings such as eye makeup enclosed in protective cello bags prior to assembling in a kit.

Protective and appealing kitting may require pre-assembly of some products prior to final assembly. You need a custom contract wrapping and packaging specialist with experience in kitting and assembly, including pre-assembly. This saves companies money when they can rely on one wrapping and packaging company to pre-assemble certain products and then perform the final gift packaging assembly as well. 

Peoria Production Solutions Provides Packaging and Kitting Solutions

Peoria Production Solutions, PPS, has been providing kitting and assembly packaging services for more than 80 years. We offer a modern facility, a highly trained and skilled staff dedicated to a high attention of detail for total customer satisfaction. PPS follows a strict quality policy as part of our ISO9001:2015 registration, practiced with top-down involvement with all employees committed to continual improvement and a job well done.

We focus on training and employee development, lean processes with value stream mapping, and cross training that eliminates potential bottlenecks. Our Enterprise Resource Planning (ERP) system tracks all incoming customer supplied material with lot code traceability and full accountability.

PPS offers secondary and specialty wrapping, packaging, and assembly to meet kitting needs for companies of all sizes. We provide secondary production and packaging solutions to some of the largest Fortune 100 companies and manufacturers with high quality and on-time delivery. Contact us to learn more about improving your packaging with great kitting and assembly 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.