FD Systems - Kitting Operations Workflow

1. Objective

Standardize kitting and prepack production into one controlled workflow that reduces machine downtime, rework, and label errors.

2. Scope

In Scope

  • Kit workorders
  • Pre-pack workorders
  • Pound packaging workorders
  • Label printing
  • Kit returns & rework

Out of Scope

  • Raw material purchasing
  • Sales order entry
  • Warehouse shipping process

PROCESS 1: Workorder Release & Label Control

Combines: Kit & Packaging Label Printing, Workorder packet preparation (implicit in others)

Objective: Release clean, complete workorders to the floor with correct labels the first time.

Inputs

  • Approved workorder (kit, pre-pack, pound)
  • BOM (Bill of Materials)
  • Packaging specs

Outputs

  • Printed labels
  • Complete workorder packet
  • Released job to production queue

Roles & Ownership

  • Production Coordinator = Release & print

Step-by-Step Process

  1. Receive approved workorder in system.
  2. Verify BOM, quantities, packaging type.
  3. Print all required labels at once (kit, inner, outer, pallet).
  4. Stage materials to production area.
  5. Operator matches physical parts to BOM during assembly.

Exceptions + Escalation

  • Missing BOM component → Escalate to Inventory Control.
  • Label mismatch → Stop job before machine start.

PROCESS 2: Production Execution (Kit, Pre-Pack, Pound)

Combines: Operating Kit Machine, Assembling & Processing Kit Workorders, Processing/Packaging Pre-pack Workorders, Processing/Packaging Pound Workorders

Objective: Execute all packaging types using one standardized production flow.

Inputs

  • Released workorder
  • Materials staged
  • Printed labels

Outputs

  • Completed packaged product
  • Quantity confirmed in system
  • Finished goods staged

Roles & Ownership

  • Machine Operator = Execute
  • Production Lead = Oversight
  • Inventory Control = Transaction posting

Step-by-Step Process

  1. Verify materials against workorder.
  2. Set up machine or packing station.
  3. Run production.
  4. Perform first-piece quality check.
  5. Continue run.
  6. Apply labels during packaging (not after).
  7. Count and verify final quantity.
  8. Move completed product to staging.
  9. Confirm completion in ERP.

Standardization Rule

All packaging types (kit, pre-pack, pound) follow the same 9-step flow.

Exceptions + Escalation

  • Machine breakdown → Escalate to Leadership immediately.
  • Quantity variance >2% → Production Lead review before close.
  • Quality issue → Stop run and inspect the full run.

PROCESS 3: Returns & Rework Handling

Combines: Customer Kit Return Breakdown/Rework

Objective: Recover value from returned kits quickly while preventing rework from interrupting production flow.

Inputs

  • Returned kit
  • RMA documentation

Outputs

  • Reusable components returned to stock
  • Scrapped components documented
  • Credit issued (triggered to Finance)

Roles & Ownership

  • Production Lead = Inspection
  • Inventory Control = Adjust stock
  • CSR = Credit trigger

Step-by-Step Process

  1. Receive returned kit with RMA.
  2. Inspection review.
  3. Sort components: Reusable / Scrap.
  4. Return reusable components to inventory.
  5. Record scrap in system.
  6. Notify CSR for credit issuance.
  7. Close RMA.

Exceptions + Escalation

  • Repeated return trend → Escalate to Leadership for review.
  • Quality defect → Root cause review.