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The high cost of kitting errors
In a fast-paced production environment, manual processes for assembling kits are highly susceptible to error. A worker, focused on speed, may accidentally grab a component from the wrong bin like an incorrect seat belt buckle. Without immediate validation, this single mistake isn't caught until it's too late, disrupting the entire assembly line and compromising the quality of the final product.
The consequences of a single mis-pick ripple downstream, leading to significant financial and operational losses. Incorrect kits result in time-consuming rework, increased scrap, and costly production bottlenecks. These inefficiencies not only drive up operational costs but also threaten product quality and your ability to meet deadlines, impacting customer satisfaction and your bottom line.
The guided and validated kitting solution
Zebra’s integrated solution optimises your kitting process by combining guided software with advanced scanning and machine vision hardware. This powerful solution works together to direct your workers, validate every pick, and automatically verify the final kit, dramatically improving accuracy and throughput from start to finish.
Potential benefits
By shifting from a manual, error-prone process to a guided and validated workflow, Zebra's solution delivers tangible outcomes that directly address your biggest kitting challenges and boost your operational efficiency.
Improved accuracy in assembly
is achieved through guided visual instructions and camera checks that guarantee the correct parts are picked
Reduced rework
is accomplished by spotting errors instantly to prevent incorrect parts from ever reaching the assembly line
Increased production throughput
is maintained as optimised routing and fewer bottlenecks keep operations moving rapidly
How the solution works
Follow guided work instructions
When a kitting order is received, Zebra rugged tablets provide optimised pick routing and step-by-step visual instructions to lead associates directly to the correct parts bin. The bright, durable touchscreens help provide clear navigation in warehouses, while industrial-grade housing protects against concrete drops and liquid ingress. By eliminating the fragility of consumer devices, Zebra tablets minimise repair-related downtime and deliver a lower total cost of ownership.
Verify final kits with machine vision
After all components have been picked, the completed kit undergoes a final check using an overhead NS42 Machine Vision camera. The system performs an automated final kit verification for part presence/absence, confirming that every required component is correctly included. This final quality gate ensures only 100% accurate kits are sent to the assembly line, providing complete traceability and peace of mind.
Turn kitting accuracy into profitability
An investment in Zebra's kitting solution delivers a strong return by minimising costly rework and production delays. By ensuring accuracy at the source, you improve overall quality and drive greater profitability.
Note:
Use case figures and savings estimates are illustrative only and may be derived from customer data, projections, or controlled testing. They do not represent guaranteed results, and actual outcomes will vary by application; customers should consult a Zebra sales representative to evaluate their specific environment.
