Imagine walking into a factory where everything just clicks; no delays, no missing parts, no confusion. Every worker knows exactly what they need, and every component is right where it should be.
While kitting isn’t new in the industry, many manufacturers still rely on paper-based processes to manage it. Workers often use printed lists to gather components, manually checking them off as they go.
Although familiar, this approach is prone to inefficiencies and errors, not to mention the environmental and operational costs of paper systems. The future of kitting lies in digitization, where kitting software transforms these manual production flows into digital, error-free processes.
Whether you’re assembling cars, electronics, or custom products, digitized kitting ensures the right parts are ready at the right time, keeping production humming along smoothly. In this guide, we’ll explore what kitting is, why it’s essential, and how the right tools, like kitting software, can take your operations to the next level.
What Is Kitting in Manufacturing?
Kitting in manufacturing refers to the process of pre-assembling individual components or parts into ready-to-use kits before they reach the production line or assembly area. These kits typically contain all the necessary items required to complete a specific task or assembly, packaged together..
Let’s look at an automotive assembly line, for example: instead of workers walking back and forth to retrieve bolts, screws, or specific engine parts from different storage areas, a pre-assembled kit is delivered directly to their workstation. This way, they have exactly what they need in front of them, when they need it.
Kitting and Assembly
Kitting and assembling shouldn’t be confused. Both are part of the manufacturing process, but occur at different places and times. Kitting happens before the actual production or assembly takes place. Workers or automated systems collect specific parts, verify their completeness, and package them together based on the bill of materials.
Assembly, on the other hand, is the actual process of putting these components together to create the final product. This is where the pre-prepared kits are used to build or manufacture the end item. Assembly involves following specific procedures and sequences to combine components in the correct way, often requiring specialized tools, equipment, and skilled labor.
Kitting in Manufacturing
Even though kitting is considered a non-added value action, it plays an invaluable role in the fulfillment process.
For example in custom manufacturing, where each product requires different combinations of parts, kitting ensures that all components are organized according to each unique specification. The process is especially useful when handling numerous small components, such as fasteners, connectors, or electronic parts in electronics manufacturing, where mix-ups could easily occur during assembly.
In factories with space constraints, kitting helps optimize the workspace by consolidating components into organized units, keeping assembly areas clear and efficient. It also plays a vital role in subassembly processes, where pre-kitted components reduce setup time and maintain smooth production transitions.
Manufacturing Bill of Materials
A B-bill of materials (BoM), the name speaks for itself, is a detailed list of all the materials and components required to manufacture a product. It serves as a blueprint for production, outlining every item necessary, from raw materials to specific parts.
A BoM is a prerequisite to start kitting. There are two primary types of BoMs:
- Standard BoM: This type is used for products that follow a fixed design with consistent materials and components. It ensures uniformity and simplifies the kitting process for repetitive production tasks.
- Configurable BoM: Designed for customizable products, this type allows flexibility by including variable components based on customer specifications or product variations. Configurable BoMs are essential for industries with diverse product offerings, as they help tailor kits to match specific requirements.
Kitting Solutions
When it comes to implementing kitting tools or systems, many manufacturers still rely on paper-based processes, where printed documents are used to list the components required for each kit. Workers typically carry these printed lists to various storage areas, manually collecting and checking off items as they go.
While straightforward and familiar, this method is prone to inefficiencies, and simply outdated. For instance, any changes to the Bill of Materials or kitting instructions require reprinting and redistributing updated documents, which can lead to delays. The manual nature of these systems also increases the risk of errors, such as missing components or inaccuracies in the final kits.
Paper-based systems don’t provide real-time tracking, which makes it trickier to spot and fix bottlenecks in the kitting process. On top of that, the environmental impact and ongoing costs of using paper add to the downsides.
Digital kitting solutions, on the other hand, use software to automate and optimize the process. Real-time updates ensure that any changes to the BoM or kitting instructions are immediately accessible to workers. Integration with inventory management systems enhances accuracy, while automated tracking and reporting provide visibility into kitting progress.
Digital systems are scalable, accommodating the needs of both small-scale and high-volume production environments. By transitioning from paper to digital, manufacturers can reduce errors, improve efficiency, and align their operations with lean manufacturing principles, minimizing waste and maximizing productivity.
Kitting Software
Kitting software is the backbone of modern manufacturing efficiency, providing the tools needed to organize, validate, and streamline the kitting process. By replacing outdated paper-based systems, this software ensures that every component is tracked, every step is verified, and no resources are wasted.
Whether in high-volume production or customized workflows, kitting software offers real-time visibility, reduces errors, and keeps the production floor running smoothly.
Azumuta as a Kitting Solution
Azumuta complements kitting actions by integrating digital work instructions and real-time validation into the process. While not a dedicated kitting software, it provides tools that help manufacturers assemble kits accurately, reduce errors, and maintain traceability.
Azumuta supports a more organized and efficient kitting process, helping teams stay on track and meet quality standards.
Integrating Digital Work Instructions
The platform enhances processes by integrating kitting into digital work instructions. For example, kitting tasks can include a detailed checklist within the work instructions, ensuring that every step is followed accurately. Operators can use scanning tools to check off items as they are added to the kit, providing instant validation and reducing the likelihood of errors.
This integration streamlines the kitting process, providing real-time feedback and maintaining consistent quality. By combining Azumuta’s digital work instructions with robust kitting software, manufacturers achieve a more efficient, traceable, and error-free operation.
Traceability
Every component is tracked within the software, creating a clear record of what’s included in each kit, who assembled it, and when it was completed. This level of visibility not only ensures accuracy but also supports compliance and quality assurance efforts.
Parts Check
The software performs real-time checks to confirm that all required components are present before a kit advances to the next stage. By catching errors early, manufacturers significantly reduce rework and maintain a consistent production flow.
Each part can be scanned or otherwise validated before being added to the kit, ensuring that only the correct components are included. This minimizes the risk of errors and improves overall quality.
Inventory
In addition to these features, kitting software integrates with inventory management systems. Inventory levels are updated in real time, providing an accurate overview of stock availability and enabling better planning and resource allocation.
Learn More About Azumuta’s Digital Work Instructions
Here’s the first step to have a paperless factory
Benefits of Kitting Software
From speeding up processes to minimizing errors, it ensures everything runs like clockwork. Here’s how kitting supported by a digital tool makes a difference:
- Reduced cycle time: By automating and streamlining the kitting process, manufacturers can assemble kits faster, reducing the overall time it takes to complete production cycles and deliver products.
- Less risk of human errors: Real-time validation and automated checks ensure that all required components are included in the kits, drastically reducing errors and the need for rework.
- Enhanced real-time visibility: With inventory levels and kitting progress updated in real time, managers gain a clear overview of operations, enabling better planning and quicker decision-making.
- Improved compliance and traceability: Every component and step in the kitting process is logged, ensuring compliance with quality standards and providing a clear audit trail for inspections and reviews.
- Consistent quality assurance: Automated part verification ensures that only the correct components are used, maintaining a high standard of quality across all production batches.
- Scalability for high-volume production: Whether for small-scale projects or high-volume manufacturing environments, kitting software can adapt to the specific needs of the operation, supporting growth without compromising efficiency.
Kitting ensures that the right parts are organized, verified, and ready for production. While traditional paper-based methods have long been used, they can’t keep up with the demands of modern manufacturing. Digital tools revolutionize kitting by offering real-time tracking, automated checks, and seamless inventory integration, reducing errors and cycle times while improving efficiency.
Tools like Azumuta’s integrated kitting flows into digital work instructions and validation processes. They bridge the gap between manual processes and full digitization, enhancing organization, traceability, and quality.
Ultimately, investing in the right tools and strategies for kitting helps manufacturers stay competitive. Whether you’re packaging electronics or assembling custom products, digitized kitting ensures that every part of your operation runs like clockwork, driving efficiency, quality, and growth.