MakitLean
Makitlean logistics kitting solution

Logistics Kitting

Kitting groups upstream all the components needed for an assembly operation into a coherent kit. By eliminating search times and synchronizing supply with production, our solutions cut assembly time by 30 to 50% on your lines.

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100% customizable, locally made, assembly time cut by 30 to 50%

Key features of logistics kitting

A flow organization that synchronizes supply with production, designed for quality, traceability and performance.

  • Reduced search and movement times in the picking zone

  • Fewer picking errors (Pick-to-Light, Put-to-Light systems)

  • Optimized storage spaces and logistics flows

  • Integration with the Warehouse Management System (WMS) and the ERP

  • Improved component traceability on the assembly line

  • Measured time gains: 30 to 50% on assembly time

What types of logistics kitting exist?

Depending on your maturity, volumes and constraints, several approaches are possible:

  • Manual kitting in the picking zone

    Specialized operators prepare kits following precise lists. Ideal for medium-sized companies or lines requiring particular attention to certain components.

  • Pick-to-Light assisted kitting

    Light indicators in picking zones guide operators to the right references to pick, considerably reducing errors.

  • Automated kitting with WMS

    Robotic systems and intelligent conveyors prepare kits without human intervention, perfect for high volumes and standardized productions.

  • Just-in-time kitting

    Supplies components to the line only when needed, optimizing workspace and reducing intermediate stocks.

  • Sequential kitting

    Organizes kit preparation in the exact order of their use on the assembly line. Particularly suited to complex productions with many variants.

Criteria for choosing your kitting solution

4 dimensions to balance to make the right choice.

Picking zone organization and storage systems

Kitting efficiency depends directly on picking zone organization. For small components, dynamic flow racks allow storing more references in a reduced space and separating picking from replenishment. For bulky items, pallet racks offer direct floor access with replenishment at upper levels.

Automation and Warehouse Management System

Integrating a WMS and automation technologies transforms kitting efficiency. The "product to person" principle reduces movement: stacker cranes and conveyors bring components to workstations where operators focus on building kits. Productivity and goods safety improve.

IT management and traceability

A high-performance WMS coordinates movements, supplies kitting stations and ensures permanent stock monitoring to avoid stockouts. Its integration with the ERP is crucial: the ERP provides the bill of materials (BOM), the WMS organizes and prioritizes preparation, guides operators and signals kit availability for the assembly line.

Operator training and specialization

Kitting quality rests on operator skill. Thorough training is essential to guarantee precision and efficiency. Specialization reduces errors and speeds the process: quick component identification, appropriate handling, precise grouping. Combined with Pick-to-Light or Put-to-Light, it maximizes productivity.

Essential components of a kitting solution

Every MaKitLean solution integrates proven components for industrial performance:

  • Dynamic storage systems

    Optimize the storage of high-rotation components in picking zones, easing access to references while separating picking from replenishment.

  • Ergonomic preparation stations

    Designed to ease operator work with surfaces suited to kit dimensions and optimized access to all needed components.

  • Warehouse Management System (WMS)

    Coordinates the entire process from picking-zone management to task scheduling, including performance monitoring and full traceability.

  • Pick-to-Light / Put-to-Light guidance solutions

    Tell operators precisely the locations and quantities to pick, considerably reducing errors on the assembly line.

  • Conveying systems

    Ensure smooth routing of components from picking zones to preparation stations, then from finished kits to assembly lines.

Frequently asked questions

  • What exactly is logistics kitting and how can it improve my production lines?

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    Kitting is an organizational method consisting of grouping in advance all the components needed for a specific operation (assembly, mounting, repair) into a coherent set called a kit. Concretely, it's the upstream preparation, in a dedicated picking zone, of all the elements that will be used together on your assembly lines. This approach eliminates search times, reduces unnecessary movement, lowers error risks and smooths the entire production process. By preparing kits according to the production sequence, you perfectly synchronize supply with line needs. Result: considerable time savings, improved quality, reduced intermediate stocks.

  • How do you set up effective kitting with a Warehouse Management System?

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    First, perform a detailed analysis of your processes to identify product families that would benefit most from kitting. Then configure your WMS to manage the detailed bill of materials (BOM) of each kit: breakdown into individual components and management of locations in picking zones. Integrate the WMS with your ERP to synchronize production planning with kit preparation. Configure dedicated zones with an optimized layout to minimize movement. The WMS must generate optimized orders (wave picking, batch picking) and dispatch them to mobile terminals or visual guidance (Pick-to-Light). Set up performance indicators to continually measure and improve. The WMS's traceability module lets you follow the complete history of each kit.

  • What real time savings do you get with a kitting system for assembly lines?

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    The savings are substantial and measurable. Our customers report a 30 to 50% reduction in assembly time after implementation. Detail: operators no longer have to search for or wait for components (15 to 20% of unproductive time eliminated). Upfront kit preparation lets you verify completeness before arrival on the line (8 to 12% of interruptions avoided). Component layout according to assembly sequence reduces micro-movements (10 to 15% additional gain). Finally, operator training is simplified (learning curve reduced by about 40%) since they no longer have to know the location of hundreds of references.

Ready to smooth your assembly lines?

Our engineering office sizes every kitting solution to measure: picking zones, ergonomic stations, WMS integration, traceability.

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