6.9 Picking, Kitting & Line Release Discipline

Kitting is the transformation of generic inventory into committed "Work in Progress" (WIP). It is not merely gathering parts; it is the digital assignment of specific assets (Lots) to a specific demand (Work Order). A sloppy kit guarantees a sloppy build. If the SMT operator has to guess which reel to use, or hunt for missing parts, the line stops. The objective is 100% Kit Integrity—the machine should never starve, and the operator should never wonder.

Picking: The Physical Transaction

Picking is a strict validation loop. Do not trust your eyes; trust the scanner.

• The Scan Logic:
  • Target: System displays Location, MPN, and required Lot (based on FEFO).
  • Action: Operator scans Location Label → Scans Part ID.
  • Validation:
    • If Scan matches → Then Quantity is deducted from Bin and added to "WIP-Picking."
    • If Scan fails (Wrong Lot/Rev) → Then HARD STOP. Do not bypass. The system is enforcing rotation or revision control.
• Quantity Discipline:
  • Full Reels: Pick the whole reel. Do not cut unless necessary.
  • Exact Count: For high-value items (CPUs, Modules), count precisely.
  • Bulk/Passives: Issue by weight or full pack. Do not count 50 resistors; issue the strip of 100 and reconcile later. The labor cost of counting exceeds the part value.

Kitting & Verification (The "Staging" Gate)

Once picked, materials move to the Staging Area. This is the Line Release Gate.

• The Kit Cart:
  • Organize the kit physically to match the machine setup (e.g., Feeder 1 to Feeder 20).
  • ESD: The cart itself must be an EPA.
• A-Part Verification (Two-Person Check):
  • For High-Value (Class A) or Safety-Critical parts, a single scan is insufficient.
  • Rule: Picker scans → Quality/Lead acts as "Verifier" and countersigns the Kit List.
• The "Clean Kit" Standard:
  • Goal: No kit moves to production unless it is 100% clear.
  • Documentation: Every kit must include the Pick List, Assembly Drawing, and any Deviation/Substitution authorizations.

Exception Handling: Shortages & Substitutions

Real-world production often requires starting with shortages. This must be a calculated risk, not a surprise.

• The "Red Flag" Shortage Rule:
  • If a kit is released short → Then the missing line item must be highlighted in RED on the documentation and digitally flagged in the MES (Manufacturing Execution System).
  • No Silent Shortages: Never let a line operator discover a missing part during a run.
• Substitutions:
  • If an alternate part is used → Then the Work Order BOM must be updated before release.
  • Risk: If the BOM says Part A but you pick Part B, traceability is broken forever. The system must match the physical reality.

Final Checklist