Kitting Bottlenecks

Kitting is a routine part of most electronics manufacturing operations. In theory, it’s simple: pull the right parts for a work order, group them into a kit, and send them off to the production line. But in practice, kitting can quietly become one of the biggest sources of inefficiency on your shop floor.

These bottlenecks often go unnoticed because they’re not as obvious as a machine failure or a line stoppage. Yet they show up in slower throughput, lost time, higher error rates, and a lack of flexibility when production needs change.

If your factory still relies on manual kitting processes, it may be time to take a closer look at how much they’re really costing you—and what you can do to fix it.

What Causes Kitting Bottlenecks?

1. Manual Part Searches

Operators often spend several minutes per part searching through shelves or bins to find the correct component, especially when part numbers, lot codes, or date codes need to be verified.

• Multiply that time by the number of parts per kit and the number of kits per shift, and the labor adds up fast.

• Worse, if a part is missing or mislabeled, the process comes to a halt.

2. Overloaded Stockrooms

Traditional rack-and-bin storage systems aren’t built for speed or efficiency. The more inventory you have, the more congested and confusing your storage environment becomes.

• Narrow aisles and crowded bins slow down picking.

• High part volumes without smart organization increase the chance of errors and further increases picking times.

3. Advance Kitting Complicates Everything

When kits are picked well ahead of time, materials get staged in temporary WIP locations where they’re hard to track. Parts sit in limbo instead of in storage or on the line.

• Production schedules shift, and suddenly kits need to be reprioritized or re-picked.

• It’s hard to know what’s available for urgent jobs, because it’s tied up in pre-staged kits.

4. Lack of Integration with ERP/MES

In many factories, picking and kitting are only loosely connected to backend systems. After a kit is built, someone still needs to manually update inventory and production status in ERP or MES software.

• This creates delays.

• It also opens the door to human error and mismatches between physical and digital inventory.

The Cost of Doing Nothing

The result of these bottlenecks? Slower builds, delayed shipments, excess labor costs, and poor use of space. Kitting becomes a drag on the entire operation, consuming time that could be spent on value-added activities.

And it’s not just about speed, it’s also about agility. When your material handling system isn’t responsive, the entire factory becomes less flexible. You can’t easily respond to last-minute changes, rush orders, or rework needs because your materials are trapped in a slow, manual system.

Smarter Kitting Starts with Smarter Storage

The good news is that modern smart storage systems can eliminate most kitting bottlenecks by replacing them with faster, more flexible alternatives. Here’s how:

On-Demand, Just-in-Time Picking

Instead of staging full kits in advance, smart systems allow you to pick parts the parts that you need right when they’re needed.

• This keeps inventory in controlled storage until the moment of use.

• Reduces WIP clutter and improves real-time inventory visibility.

Faster, Error-Free Retrieval

Smart storage automatically locates and presents the correct part based on predefined picking rules (FIFO, lot code, MPN, etc.).

• Picking times drop from minutes to seconds.

• No need for double-checking part numbers or dates, so mistakes are virtually eliminated.

ERP/MES Integration

Smart systems can transact picked materials automatically, updating your ERP or MES software in real time.

• This closes the loop between physical inventory and digital records.

• It also frees up your team from tedious data entry.

Scalable for High-Mix, Low-Volume Environments

Smart storage isn’t just for high-volume production. In fact, it’s ideal for high-mix environments where kitting complexity is even more pronounced.

• Handle multiple jobs, revisions, and lot tracking requirements with ease.

• Reduce chaos without sacrificing flexibility.

Final Thoughts

Kitting doesn’t have to be a bottleneck. In fact, with the right systems in place, it can become a streamlined, reliable part of your operation that supports faster production and more accurate builds.

If your team is constantly searching for parts, repicking kits, or firefighting inventory issues, it's time to stop accepting kitting bottlenecks as a normal part of manufacturing. There’s a better way and it starts with rethinking how you store, pick, and deliver materials to the line.

Smart storage and just-in-time kitting aren’t just nice-to-haves; they’re key tools for building a faster, more flexible, and more profitable factory.