An In-depth Look at Cogiscan's Kitting Control Module

Despite its simplicity at the surface, the kitting step in the electronics manufacturing process can be deceptively complex and resource-intensive. Often overlooked as place to optimize, kitting is in fact a critical phase within the Surface Mount Technology (SMT) sector, where the accuracy and efficiency of job preparation can greatly influence the entire production workflow. Any errors or delays in kitting can cause quality issues and a waste of resources.

In SMT, the kitting operation is the process of gathering and organizing all the necessary components and materials before they are placed onto the PCB. This step must be flawlessly executed; otherwise, there can be major repercussions down the line. Common issues such as the pulling incorrect components or quantities can cause machine downtime, an increase in work-in-progress (WIP), customer dissatisfaction, as well as the need for additional resources to rectify the issue.

The Kitting Control module from Cogiscan addresses these challenges head-on. It simplifies the material picking process by providing operators with a detailed kit list. This list includes precise component locations, exact quantities required for the job, and specific loading instructions. With the ability to integrate seamlessly with stock room inventory shelving or intelligent storage towers, the system ensures that the right components are picked and delivered, reducing the likelihood of errors while optimizing the kitting process for faster turnover. Cogiscan’s Kitting Module is included in TTC Go!, our mobile application for Track, Trace and Control on the production floor.

The efficacy of Cogiscan's Kitting Control module is not just theoretical. A Tier 2 Global EMS company reported a dramatic reduction in kitting time for large kits—cutting down from 4 hours to just 1.5 hours—a 62.5% decrease in time spent preparing kits for production. This significant improvement is thanks to the apps ability to optimize the kitting route and eliminate redundant processes such as buddy checks, which were previously required.

Flexibility is also a cornerstone of the Kitting Control module, allowing for custom-defined rules that align with a factory's unique operational preferences. Manufacturers can configure the system to follow FIFO (First-In, First-Out) rules, prioritize the consumption of partial reels, or select full reels that will last the duration of a job to enhance line productivity and minimize material replenishment times. This level of customization ensures that the kitting process is perfectly tailored to the specific needs and rhythms of each production environment.

Cogiscan's Kitting Module automates and error-proofs the material kitting for all production jobs. It checks for material shortages before production begins, automatically reserves materials for specific kits, prevents the accidental use of unauthorized materials, and ensures the availability of the exact quantity of components needed. Automatic pull requests are also sent to Storage Tower(s), further automating the process. By offering a sophisticated solution that addresses the intricacies of the kitting process, it enhances efficiency, reduces errors, and ultimately leads to greater customer satisfaction. As electronics manufacturers continue to seek ways to optimize their production lines, tools like Cogiscan's Kitting Control module will continue to be integral components for leading manufacturers globally.