WCM Logistics/Customer Service Pillar

KIT-ting

Supply Chain Management

Industrial Logistics
 Index

1. Introduction

2. Guidelines

3. Yamashina comments on KIT

4. How to develop KITs

5. Examples

November 2010 Supply Chain Management KIT-ting - 2

 Introduction

This document provides information and suggestions on KIT implementation.

A KIT is a group of several different parts to be delivered to a work station:

• at the same time
• at the same point of use
• on the same cart/ trolley

The KIT delivery can be:

• Just In Time
• Just In Sequence
• Commissioned

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 Guidelines (1/2)

Definition
• Specific collection of parts for the assembly operations of one defined end product
(truck, tractor, machine or component in a subassembly)
• One KIT is always in one container (fix) or on one cart (movable)
• One KIT can be for one or more workstations. If the KIT is used in several workstations
it is called Commissioning KIT and it follows the truck/tractor/machine along on the
assembly line.

Benefits Limitations

 The preparation of KITs is a non-value

 Reduces required assembly space
added activity
 Reduces assembly operators’ NVAA
 Likely to increase storage space (not at
(walking/searching time)
line side)
 Reduces WIP/ improves its control
 Additional planning/control required
 Increases the line flexibility for products
 Additional handling might increase risk
changes or new products introduction
of parts damage
 Alleviates training of line workers
 Defective parts in a KIT will lead to
 Decouples Inbound from In-house flows
immediate part shortage

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 Guidelines (2/2)
When to implement a KIT
• Limited line side space
• Long walking and search times for
assembly operator
• Accumulation of human errors in picking
parts at the assembly line
Who prepares KITs & how
• Dedicated picking operators
• Use movable KIT trolleys
• Design KIT trolley in a way that operator
knows which part goes where (KIT design
to be done together with WO pillar)
• Parts with quality issues to be checked
before/while KIT-ting
November 2010 Supply Chain Management
What to prepare in KIT
• Items belonging to A.1.2, A.3.1 and B.2
classes, meaning low communality (option)
parts that can be carried by hand (sizes S -
M).
• Parts which might be damaged during
handling require additional evaluation
Where to prepare a KIT
• KIT-ting area can be located close to the
assembly line or in the warehouse.
• It can be centralized to serve several areas
or decentralized (many KIT-ting areas
serving different assembly areas each)
KIT-ting - 5
 Commissioning KIT

The Commissioning KIT contains items to be assembled in several workstations and it

follows the truck/tractor/machine along on the assembly line.
Traditional assembly Commissioning trolley

Kitting
area

Characteristics:
• No separation between value added & non
value added activities
• Many movements (walking and searching)
• Stock in circulation and space utilization
are usually undefined
• Bin size/ line side inventory determine the
length of the assembly line
• Replenishment through patrolling
Characteristics:
• Work is done following the “surgeon and
nurse” principle
• Reduction of movements linked to a
productivity increase
• Stock in circulation and space occupied are
significantly reduced at line side
• Replenishment through “PULL” logic

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 Yamashina comments on Kit

1. KIT-ting is a cost! Because it implies additional handling. Use only if strictly required
and when considerable NVAA reduction can be achieved.

2. KIT must be small (and NOT heavy) in order to bring it as close as possible to the
assembly point.

3. One picking motion/ one assembly movement is the key concept for NVAA reduction
at the assembly line.

4. One-piece flow is the target also for kits. More kits in the cycle means higher NVAA in
managing them

5. Implement Poke Yoke logic to eliminate Human Error and facilitate/ guide assembly
operations

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 How to develop KITs (1/5)

Process steps to develop a KIT

1. Identify parts to be delivered in a KIT: choose A.1.2 and A.3.1 class items (low
commonality/ many variations) as well as B.2 class items and critical items pointed out by
the WO team (e.g. human errors occur often in picking activity at the assembly line).
2. Collect all the parts to be put in the KIT (for try-outs use damaged parts if possible).
3. Identify for these parts the order of consumption at the line and the point of use (where
they are assembled on the machine)
4. Arrange the parts based on the assembly sequence and the point of use. Take photos of
the arrangement.

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 How to develop KITs (2/5)

5. Brainstorm potential KIT concepts. The “One-Motion Picking” logic has to be considered
when designing the trolley (see table below), in order to minimize operator NVAA
• If the KIT is common for 100% of the machines, then a dedicated design will work.
• If the KIT has low commonality, then a flexible KIT design will be required.

One – Motion Picking Process

Activity Points of attention
Allow the accessibility of parts during both picking
1 Define the sequence of KIT preparation/loading
and assembly
Draw on the ground the line that the operator has to
2 Define the sequence of picking
follow during the picking
3 Define the correct way of picking
Avoid NVAA of the operator during the picking
4 Define the correct direction of picking
Define the correct position of the part inside the
5 container
Be consistent with the sequence of assembly

Define the tray position and shape – where the part

6 is placed
7 Define the material tray
Define how to organize and manage the picking
8 activities

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 How to develop KITs (3/5)

“One-motion picking” suggests to place the items on the KIT in a way that guarantees easy
picking for the operator and avoids NVAA such as:

The front lamp is

located in the KIT in
the exact position it
will be assembled onto
the bumper above

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 How to develop KITs (4/5)

6. Establish ranking criteria for the KIT concepts and identify the “best” KIT concept to be
implemented.

7. Create a prototype trolley in order to test the solution.

In this step it is crucial to work with the WO team to agree on the best material
presentation in order to minimize operator’s movements

Ergonomics must be guaranteed for both the KIT-ter, who prepares the KIT, and the line
operator, who picks parts from it.

Items are arranged on the KIT based

on the point of use on the machine

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 How to develop KITs (5/5)

8. In case of a commissioning KIT, choose a proper place to hook the trolley to the
machine/ assembly line.

9. Test comfort/ ergonomics/ stability during the different phases (preparing the KIT,
delivering it to the line, picking parts at the assembly line) and modify it if necessary.

10. Review the parts presentation by using the One-Motion Picking logic.

11. Define the total number of trolleys to be implemented in the logistics flow. Consider the
number of trolleys in the KIT-ting area, the number of full trolleys at line side, the number
of trolleys in transit between the assembly line and the KIT-ting area

12. In case of a commissioning KIT, build all the prototypes required for a complete train.
Test and simulate the entire process

13. Set up a complete system of trolleys

14. Set up a standard procedure to define the cycle for logistics train, detailing all the
activities step by step.

15. Establish a picking list to communicate exactly which parts and related quantities are
required in the KIT
For details on picking tools please refer to “07.LC.T._Picking systems”

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 How to develop KITs: Some considerations (1/5)

The KIT has to be as small as possible, so it can be easily moved and brought very close to
the point of use by the operator. Only in this way NVAA can be significantly reduced.
BEFORE AFTER

Left side KIT

Right side KIT

1 KIT per tractor 2 KITs per tractor

Kit is too big!
High NVAA

Kit Sx
K
I
T
Kit Dx

- Jesi plant -

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 How to develop KITs: Some considerations (2/5)

• During KIT development, the following factors should be

considered:
• available space at the workstation
• dimensions and weight of all items in consideration
• ergonomics
• assembly sequence
• replenishment cycle time

• In particular the replenishment time is important to define how

many KITs have to be put on the same cart

• In the beginning, when the delivery process is not yet final, consider even a higher
number of KITs in the same cart - to be reduced once the flow has been optimized and
standardized
• When building KIT carts for different workstations, be consistent with the number of KITs
(for each cart use the same number or a multiple) in order to guarantee an easy and
time efficient delivery system

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 How to develop KITs: Some considerations (3/5)

• Poke yoke devices should be implemented as visual aid to help both the KIT-ter and the
worker at the line (shape of the items or even better pictures)
• In case of KIT trays, each item has a specific position defined by its shape. By using sponge/
foam materials for the shape, items are also protected from damages during transport

Burlington

Curitiba IVECO Madrid uses

etaphoam material to
create part number shape
on the KIT, identifying
Jesi each position with a photo

IVECO Brescia focused on

having a clear identification
of position for items in the
In case a p/n in Jesi is not required for a specific model, a KIT(with p/n, picture and
visual aid (sign) is implemented to advice the operator at the sequence number)
assembly line (e.g. put GREEN TAG in the empty spot).

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 How to develop KITs: Some considerations (4/5)

• Adding visual aid to the KIT related to the workstation where each item has to be
assembled will help the operator in picking and assembly operations
• Visual aids can be colours as well as labels reporting the number of the workstation (or in
case all items are assembled on the same workstation, it’s useful to arrange them by
“phase” of assembly)
Items for
phase 1
Items for Items for
workstation 1 workstation 2

Items for
phase 2

Items for
workstation 3 Items for
phase 3
KIT containing items for 3 different KIT containing items for the same
workstations marked with different colours workstation, arranged by assembly phase

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 How to develop KITs: Some considerations (5/5)

• The sequence of assembly is crucial to

avoid interference among parts used in 1 2
different workstations

• Each item/group of items should be 5 4 3

identified by labelling, indicating the
specific workstation where it has to be 7
assembled. 6

• The labels enable simple visual checks on

each workstation to see if items have been 8
(not) assembled on the previous station.
This allows to recover this type of mistakes
quickly, without having to wait till the end of
the line to recover the mistake in rework/
repair.

The KIT in the picture is too big! The positive value of the example is in its sequence logic.
This implementation is acceptable only in the first stage (as temporary solution) in order to
create the flow. Then the KIT must be reviewed and optimized to reduce operator NVAA

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 Example 1: St Valentin

• St. Valentin introduced a KIT

which enters the cab through the
rear window - “as close as
possible to the point of use”

• The operator can pick the parts

without getting out of the cab,
with a significant NVAA reduction

• One picking motion in place

• Very good ergonomics

guaranteed for the operator,
since all the parts are available
at easy reach

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 Example 2: Antwerp

Antwerp designed a specific Locked to the driveline, the 2 “wing” panels

KIT to manage tubes in the can be opened so all items are available
APH assembly line very close to the point of use, in the proper
position (one assembly movement)

The trolley is pushed into

the driveline

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 Example 3: Basildon

• In Basildon, KITs are delivered in one

piece flow

• The KIT is small and light and it’s brought

very close to the point of use

• Also the hardware is available in the KIT.

The replenishment is managed with a
visual reorder level, checked in the KIT-ting
area when the KIT is prepared.

OGS Stations – KIT Flow

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 Example 4: Antwerp

• Antwerp designed specific trolleys for

KIT-ted parts:
• plastic boxes with dividers (for
parts to be washed)
• templates with specific and
unique spot for each p/n

• KITs are sequenced on the trolley and

the number of the sequence is hand-
written on the item by the person who
prepares the KIT
Handwritten
sequence • All trolleys contain a dedicated frame/
number level for the return of empty boxes/
templates

• POKE YOKE device is in place to

avoid mistakes while KIT-ting

• The templates are colored to

distinguish KITs (different colors for
different final products)

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 Example 5: Jesi

Jesi developed trolleys to

arrange KITs based on the
ergonomic position of the
operator (platform assembly line)

• Trolley contains also • 1° Picking Level

C items, arranged in For the Upper frame assembly
trays (the operator is on top of the
machine)
• Colours on the trays
are related to the
specific product • 2° Picking Level
family For normal position of
assembly

• 3° Picking Level
For Lower frame assembly (the
operator is underneath the
machine)

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 Example 6: Zedelgem

Zedelgem has designed a specific engine trolley.

The empty trolley goes through the kitting area where the items necessary for the engine
sub assembly are gathered. The cart is then pushed into the engine line where the engine
has been brought from the warehouse.
The cart is made in a way that it will wrap the engine and aid the operator with the
assembly operations until the engine is moved with a hoist to the main assembly line.

1 2 3 4

The trolley has been prepared in the The trolley is put on The engine is brought The engine is brought to the
kitting area with the items that are the line. to the line side to be main line through a hoist.
necessary to perform the engine sub located in the cart. The cart is empty and returns
assembly. to the kitting area

1 4

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 Example 7: FPT Bourbon Lancy

FPT Bourbon Lancy has designed a specific engine trolley.

The trolley is pushed into the driveline and it is made in a way that it wraps the engine and
aids the operator with the assembly operations.

BEFORE

Engine Kit

AFTER

Engine Kit

Less NVAA
Ergonomics guaranteed

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 Example 8: IVECO Suzzara

IVECO Suzzara has

designed a specific engine
trolley. Particularities are:
• The kit preparation time is
synchronized with the AGV
line system: the operator
takes the empty kit at the
entrance of the U shape
and makes it available
when the AGV is at the
end of the kitting area.
• The parts location in the kit
reflects the assembly
sequence (different color =
different workstation).
• The kitting is structured in
a way that minimum
movements of the operator
for preparing the kit are
guaranteed.

November 2010 Supply Chain Management KIT-ting - 25