Kitting 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.
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.
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.