ASSEMBLY & KITTING

Kitting & Assembly Examples:

Experience you can trust in Columbus, OH

Sort and Pack has the facility and the experienced staff for all of your kitting and assembling needs. Our 40,000-square-foot warehouse and fulfillment center can morph into the most efficient configuration that will save your business time and money.

From simple hand assembly projects to elaborate outsourced kitting operations, we have a trusted, experienced team to provide quick turnaround and timely results. We work with a variety of businesses and industries — such as print, retail, wholesale, beauty, medical supplies, promotional, manufacturing and advertising. Whether it’s a one-time project or quarterly fulfillment needs, Sort and Pack offers assembling expendable packaging that features nesting, multipart assemblages for automotive parts suppliers, etc.

Frequently Asked Questions

  • What is kitting?
  • What items can be kitted?
  • How does kitting save time and money?

Kitting is part of the fulfillment process that refers to the assembly of individual items into ready-to-ship sets or kits. In most cases, completed kits are placed into storage to be shipped at a later time. Kits are generally assigned a unique SKU number to differentiate the assembled kit from its individual components and to allow the kit to be inventoried and tracked as a single unit.

Any items that are regularly sent out as a consistent set can be kitted. Kitting is often used for  promotional literature, product samples, instructional packets, demonstration and display materials, game sets, media and welcome kits, new product launches, dealer and franchise supplies, etc.

When many kits are distributed, it becomes more cost effective to have them pre-built in batches. Pre-assembling kits in large batch quantities offers several advantages over waiting to pick and pack the components as orders arrive.

The more kits produced at one time, the lower the assembly time will be for each kit. This is because the mass production of kits is a more linear operation, with less starts and stops, than producing a kit here and a kit there.

When kitting in bulk, all the components of the kit can be positioned in close proximity to each other to streamline the gathering and assembly process, as opposed to locating and retrieving the components of kits that are prepared separately as orders come in. It is much easier and faster to prepare a pre-assembled and/or pre-packed kit for shipment.

Sort and Pack’s efficient pick-and-pack processes

Sort and Pack can reduce turn times with a process that streamlines kitting, assembly, pick/ pack and shipping for our clients. We have a high throughput capacity compared to other pick-and-pack firms in the industry. We consistently build millions of units each month, sometimes with 20 or more parts, creating more than 40 million touches in any given month.

Sort and Pack’s product assembly team is 99% accurate, resulting in reduced turn times for companies by as much as 70%, as well as reduced product assembly costs by as much as 80%. Whether it’s a simple media kit, a product or a complex mix of options, Sort and Pack can assemble, pick, pack and ship just about anything.

The Sort and Pack planned receipt module guarantees that we won’t receive your items blind. When we kit or assemble products, everyone involved — including the clients — know exactly what to expect in real time. We keep our clients in the loop every step of the way.

Our services are not limited to assembling kits and manufacturing products.

We make the entire manufacturing process more efficient, promising our clients these objectives:

  • We ensure materials and products are available for production and delivered to customers
  • We maintain the lowest possible level of inventory
  • We plan all manufacturing activities, including delivering schedules and purchasing activities
Clothing Pick and Pack Services Sewing Laundering Sort and Pack
Cosmetics Industry Assembly and Kitting Fulfillment Services Sort and Pack

Fulfillment Services Include:

How Sort And Pack saves you time and money

If you had to make 10 peanut butter and jelly sandwiches, it makes sense to make them all at once. Here’s why: You gather bread, a knife, jars of peanut butter and jelly. Then, you make all 10 sandwiches at once. It doesn’t make sense to make 5 sandwiches now, clean everything up and go through the process again. Just like making peanut butter and jelly sandwiches, retaining pre-assembled kits in stock saves time, because when an order is placed, our team doesn’t have to stop and pull all of the various components together.

As more kits are produced at one time, the assembly time per kit is reduced by avoiding the stops and starts associated with assembling orders as they come in. Distribution, then, becomes simplified with pre-kitted inventory, because all that’s left is to affix a shipping label and send the package on its way.

Warehouse and assembly services allow you to:

No matter what your project entails, we offer quality corrections and inspections that enable kitting services specifically-tailored to your unique needs:

Assembly & Kitting Case Studies:

Storage and by order pick/pack of a clothing closeout of several hundred SKUs, 20,000+ units

  • Pallets received and sorted by SKU
  • Stored on floor by item to create a pick area
  • Pick by case orders referencing case IDs from customer provided pick lists
  • Pick by unit orders referencing case IDs from customer provided pick lists
  • Label pallets per instructions for LTL shipment to stores
  • Cycle count by request

Storage and by order case pick of 10 truckloads of packaged candy

  • Receive by trailer candy with expiration date sensitive multi-SKUs; solid and mixed product pallets
  • Store by SKU on pallets of a standard quantity
  • Pick by case order
  • Label pallets per instructions for LTL shipment to stores
    Cycle count by request

Unload and storage of 40 of trailers from a hardware store liquidation

  • Receive solid carton multi-SKU merchandise and store by pallet
  • Verify merchandise against manifest or packing list
  • Maintain inventory of items received by inbound trailer
  • Re-ticket as necessary
  • Pick orders by SKU
  • Ship orders via truckload and LTL as directed by customer
  • Unload and storage of 17 of trailers from office store liquidation
  • Receive solid carton multi-SKU merchandise and store by pallet
  • Verify merchandise against manifest or packing list
  • Maintain inventory of items received by inbound trailer
  • Re-ticket as necessary
  • Pick orders by SKU
  • Ship orders via truckload and LTL as directed by customer
  • Receive component parts from multiple vendors
  • Place display tray in decorative box base
  • Insert merchandise into specific location and order; gloves required to eliminate fingerprints on merchandise
  • Place box top on base
  • Insert kit into polybag
  • Generate and affix barcode label
  • Pick pack multiple kits into master carton
  • Maintain in-house inventory of components for build assembly
  • Pull required components per customer “Build of Materials” request
  • Digitally document components by build
  • Perform simple to complex unit carton assembly
  • Pack into master cartons
  • Generate master carton labels
  • Palletize for shipping
  • Received gaylords of bundled, shrink-wrapped, banded seasonal catalogs
  • Remove banding and shrink-wrap form 25-unit packs
  • Quality inspect cover of catalogs; replace defective catalogs to maintain pack integrity
  • Shrink-wrap and double band each pack
  • Re-pack into gaylord
    Receive multiple sized banners/posters on printer skids
  • Affix channel guides to printed materials
  • Roll-box and label items
  • Pick-pack and ship completed kits
  • Fold 2-pocket gusseted folder
  • Affix 2-sided tape to form pockets
  • Collate “stair-step” printed materials and insert into folders
  • Box in predetermined quantities
  • Label cartons
  • Display Assembly and Fill Units
  • Receive component parts from multiple vendors
  • Build corrugated desktop display
  • Fulfill display with component parts
  • Place in master carton
  • Label carton
  • Ship to individual locations
  • Replenish as required
  • Display Assembly and Fill Units
  • Receive component parts from multiple vendors
  • Build corrugated desktop display
  • Fulfill display with component parts
  • Place in master carton
  • Label carton
  • Ship to individual locations
  • Replenish as required

850,000 units in 6 weeks

  • Receive component parts of samples and pamphlets
  • Heat seal samples and pamphlets into take-away bag
  • Pick/pack and ship over a million bags

1,200 units

  • Receive bulk packed shirts — size, color and gender specific
  • Pick/pack shirts to be sent to each members of the national sales team with appropriate correspondence
  • Create UPS labels with address file provided by customer