Do you want the best bang for your buck? Consider incorporating kitting into your organization. Kitting is a strategy that involves taking components from multiple SKUs and combining them into one kit with one SKU.

A lean kitting process can help speed up the overall manufacturing or assembly process and reduce labor costs. Kitting projects are more efficient because they require less maintenance and oversight. The concept of kitting can be used in nearly any company. Kitting combines various products and components so users always have the right inventory at the right time.

Lean manufacturing aims to remove bottlenecks and waste from work processes to improve efficiency. Waste is any action or process that does not add value to the customer. There are eight wastes of lean manufacturing:

  1. Transport – wasted time, resources and costs when moving materials
  2. Inventory – waste resulting from excess products
  3. Motion – wasted time and effort
  4. Waiting – waste from time spent waiting for processes
  5. Overproduction – waste from making more products than necessary
  6. Over-processing – waste related to more work required
  7. Defects – waste from a product failing to meet expectations
  8. Skills – waste due to unused talent

The first step to reducing waste is to recognize that it exists and having an effective method for identifying the waste. It is important to think about the final product and customer and work backwards to the very beginning of the manufacturing process.

Consider these steps in kitting that eliminate SKUs and streamline the process.

  1. Walk through the shop floor – Analyze how parts are organized. Lean methods require an in-person observation of where work is performed and to what value that adds to the overall project. Taking note of all of the areas that could result in potential waste is a great way to visualize the process. Is there a way to conserve energy and costs by consolidating inventory?
  2. Identify inefficiency – Check for bottlenecks in process and take note of any components that are hard to track. Material that is not combined can be difficult to keep track of and store. Consider combining products to eliminate any added waste.
  3. Work together – In order for the lean kitting process to be successful, the entire team needs to work to identify waste and improve processes. Once areas are identified for inefficiencies, collaborate to find solutions that one might not have identified on their own. Discuss solutions with people that are a part of every step of the process.

Once you have identified all of the areas of waste and potential solutions, work with the distributor to continue improving efficiencies for the kitting process.

Peoria Production Shop Practices Leak Kitting

Peoria Production Shop offers more than 80 years of experience in kitting and assembling various products and components for some of the largest companies in the world.  We practice a strict quality policy as part of our ISO9001:2015 certification and provide full lot code traceability of all parts and components with our Enterprise Resource Planning (ERP) system.

We practice Value Stream Mapping (VSM) to identify any bottlenecks in the process and cross-train employees for collaborative and efficient workflow. 

Peoria Production Shop is a leading kitting and assembly house for Fortune 100 companies and businesses of all sizes.  Since we are a not-for-profit organization, focused on creating jobs rather than profits, we provide the unique ability to deliver the most cost-effective solutions to manufacturers and distributors.  Contact us to learn more about our high-quality and cost-efficiencies with lean kitting processes.

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