What is Kitting in a Warehouse?

Kitting is a process employed in warehouse management where individual items are grouped together to form kits or packages. These kits contain all the necessary components or parts required to fulfill specific orders or complete certain tasks. By pre-assembling these kits, warehouses can streamline their operations, enhance efficiency, and deliver products more swiftly to customers.


Warehouses play a crucial role in the supply chain, serving as storage and distribution centers for various products. Efficient warehouse management is essential for businesses to meet customer demands and maximize operational efficiency. One approach that has gained popularity in recent years is kitting. Kitting is a process employed in warehouse management where individual items are grouped together to form kits or packages. These kits contain all the necessary components or parts required to fulfill specific orders or complete certain tasks. By pre-assembling these kits, warehouses can streamline their operations, enhance efficiency, and deliver products more swiftly to customers.

Benefits of Kitting in a Warehouse

Improved Efficiency

Kitting significantly improves warehouse efficiency by reducing the time spent searching for individual items. By assembling kits in advance, workers can quickly access all the required components, reducing the picking time and increasing overall productivity. For example, in an e-commerce warehouse, kitting allows order pickers to gather all the items needed for a specific order at once, eliminating the need to traverse the warehouse multiple times.

As we take care of the kitting for you this frees up your time to focus on your business. Our goal is to help you work on the things that are the highest and best use of your time. We can handle this part of your business while you focus on scaling your brand. 

Reduced Order Picking Time

The process of picking individual items for each order can be time-consuming. Kitting allows for the consolidation of frequently ordered items, reducing the number of picking operations required. This streamlined approach results in shorter order fulfillment times and increased customer satisfaction. For instance, a warehouse fulfilling subscription box orders can pre-kit the boxes with the common items across all subscriptions, minimizing the time needed to pick each individual item for every order. 

A lot of brands outsource their kitting and assembly because they run into limitations with space in their warehouse. We have a lot of space in our warehouse that is dedicated to kitting to make sure that we can be as efficient as possible for our customers. We have laid out our warehouses in a way that allows us to be flexible as you scale your business and as your kitting needs increase.

Minimized Errors

When assembling kits, there is less room for error compared to picking individual items for each order. By grouping the necessary components together, warehouses can minimize the risk of missing items or including incorrect ones in the order, improving accuracy and customer satisfaction. For example, in a mobile phone assembly warehouse, kitting the necessary components for each phone model ensures that the correct parts are included in every kit, reducing assembly errors and subsequent customer returns.

Launch Fulfillment has a no leakage policy. We are committed to you and your business and we want to make sure that all the products that you ship to us make it to your customers. We don’t tolerate theft, and we replace and products that are broken or damaged on our property. This gives you the peace of mind that we are putting you and your customers first.

Streamlined Inventory Management

Kitting simplifies inventory management by allowing warehouses to track kits as single units rather than individual components. This reduces the complexity of stock control and enables better forecasting and planning for inventory replenishment. For instance, a medical supplies warehouse can track the number of pre-assembled kits for specific medical procedures, making it easier to monitor inventory levels and plan for replenishment.

It is nice to have some of your products fully assembled and ready to sell in a full kit and then the rest of the inventory ready to be assembled as though other kits get sold. As inventory moves off the shelves we will continue in the kitting proces to make sure that you never run out of your products.

The Kitting Process

The kitting process involves several key steps to ensure the successful assembly of kits:

Planning and Preparation

Before initiating the kitting process, it is crucial to plan and prepare adequately. This includes identifying the components needed for each kit, determining the optimal kit quantities, and establishing a suitable location for storing the kits. For instance, in an automotive parts warehouse, careful planning ensures that the right combination of parts is available in the right quantities to support various repair kits.

As part of the planning process, each product will have a set kitting process so it is assembled the same way everytime to make sure that the quality of the process is consistent. That way your product gets to the customer the same way everytime. 

Gathering Materials

Once the planning is complete, the next step is to gather all the necessary materials and components for the kits. These items are typically retrieved from the warehouse’s inventory and brought to the kitting area. For example, in a cosmetics warehouse, the kitting area may be stocked with different types of creams, lotions, and makeup items to create customized beauty kits.

We have a vast network of trusted suppliers so if you or your team ever needs help finding materials for your kits please reach out to us and we can connect you with our network to make sure that you are getting everything you need when you need it.

Assembling Kits

In this stage, the workers assemble the kits by combining the required components in the predetermined quantities. Attention to detail and accuracy is crucial to ensure that each kit contains the correct items and quantities. For example, in an electronics warehouse, workers may assemble kits containing smartphones, charging cables, and screen protectors.

Great fulifllment companies set up kitting stations in order to keep your products organized. As your products get assembled they are all getting tracked through the inventory management system so you know how many products you have that are ready to be sold at any given time. 

Product kits can come in all shapes and sizes. Launch Fulfillment’s kitting team is excellent at helping you product your high quality product to each of your customers every time. Our sales team will talk with you about your process and make sure that we can make sure we are meeting your and your customers expectations on every order. Whether it is a small kitting process or a large one we are happy to help. 

Quality Control

After assembling the kits, quality control checks are performed to verify that each kit is complete and accurate. This step involves inspecting the kits for any missing or incorrect components, ensuring that the kits meet the required quality standards.

By clicking on the following link, you can access the article: Kitting Defined. It offers valuable insights into kitting processes and can further enhance your understanding of how kitting can improve efficiency and streamline operations in a warehouse.

Best Practices for Kitting in a Warehouse

To optimize kitting operations, warehouses should consider implementing the following best practices:

Proper Organization and Labeling

Maintaining a well-organized kitting area is essential for efficient operations. Each kit should have clear labeling and identification to minimize confusion and errors. Proper organization and labeling enable workers to locate and retrieve kits quickly. For instance, in a toy warehouse, kits can be organized based on age groups or specific themes, with clear labels indicating the contents of each kit.

Having label machines that can help speed up the process and make the kitting team more efficient is important. It is important to make sure that the kitting team has all the other equipment that they need in order to assemble the order correctly so there aren’t any delays in the process. 

Utilizing Technology and Automation

Technology plays a significant role in optimizing warehouse operations, including kitting. Implementing barcode scanning systems and warehouse management software can enhance accuracy and speed up the kitting process. Automation can also be employed for repetitive tasks, further improving efficiency. For example, in an electronics warehouse, barcode scanning technology can ensure that the correct components are included in each kit, reducing manual errors.

Depending on the kit, using robotics to help speed up the process to make employees and warehouse workers more efficient can drastically reduce costs, and increase productivity. Each kit is a little different, but depending on the situation there are lots of different applications and approaches.

Regularly Reviewing and Updating Kits

As customer demands evolve, it is essential to review and update the composition of kits regularly. By analyzing sales data, customer feedback, and market trends, warehouses can ensure that their kits remain relevant and meet customer expectations. For instance, in a home improvement warehouse, kits can be updated based on changing trends and customer preferences, ensuring that the kits align with the latest DIY projects or home renovation needs.

As we update kits it is important to continue to keep the Launch Fulfillment team in mind. As we are working we look for efficiencies and we can help you understand what might be good or valuable to your customers are you are in the process of expanding the kits you are having us work on. 

Training and Communication

Proper training and clear communication are crucial for successful kitting operations. Warehouse staff should be trained on the kitting process, quality control procedures, and the importance of accuracy. Effective communication channels should be established to address any issues or updates related to kitting. For example, in a food and beverage warehouse, regular training sessions can educate workers on assembling kits that comply with specific dietary requirements or allergen restrictions.

Our goal at Launch Fulfillment is to help you run as efficiently as possible. We set up regular calls with you and your team to make sure that everything is working the way that it should and to discuss options on how a process could be improved. Also we love getting feedback from you to help us as you see ways to better run your business.

Challenges of Kitting in a Warehouse

While kitting offers numerous benefits, it also comes with its own set of challenges. Some common challenges include:

Inventory Management and Stockouts

Maintaining accurate inventory levels and avoiding stockouts can be challenging when dealing with assembled kits. Proper inventory management systems and regular monitoring are essential to ensure an adequate supply of kit components. For example, in an e-commerce warehouse, real-time inventory tracking systems can help prevent stockouts by alerting warehouse managers when kit components are running low.

It is important to make sure tha you are managing all the parts that need to be assembled into a kit. If there is a delay on one item in the kit it is important to communicate that to the team to make sure that everyone is on the same page about what should be done in that scenario. 

Space Constraints

Assembling kits requires dedicated space within the warehouse. Space constraints can limit the number of kits that can be prepared simultaneously. Warehouse layout optimization and efficient space utilization techniques are vital to overcome this challenge. For instance, in a furniture warehouse, a well-designed kitting area with proper storage racks and shelving can maximize space usage.

Complexity of SKU Variations

Kitting becomes more complex when dealing with a large number of SKU (Stock Keeping Unit) variations. Managing and tracking different kit configurations can pose challenges, requiring robust inventory management systems and meticulous record-keeping. For example, in a computer hardware warehouse, kitting different configurations of components for custom-built PCs requires careful SKU management and tracking.

Launch Fulfillment has been in the fulfillment industry for a long time, and we can help advise you in how SKU’s can work for your company. We can also work within your process if you already have an established SKU process. 

Kitting vs. Assembly

It is important to differentiate between kitting and assembly processes in a warehouse. Kitting involves grouping individual items together to create kits, while assembly refers to the process of putting together components to build a final product. Kitting is typically done in preparation for future orders, whereas assembly is the final step in the production process. For example, in a furniture warehouse, kitting may involve packaging hardware, instructions, and accessories with each piece, while assembly would involve constructing the furniture from the components.


Kitting is a valuable strategy for optimizing warehouse operations and improving overall efficiency. By grouping necessary components together in kits, warehouses can reduce order picking time, minimize errors, and streamline inventory management. Implementing best practices, such as proper organization, utilizing technology, and regular kit reviews, can further enhance the effectiveness of kitting in a warehouse.


Q: What industries benefit from kitting in warehouses?

A: Kitting can benefit various industries, including e-commerce, manufacturing, electronics, automotive, and medical supplies. We also work with the supplement, emergency preparedness, and the long term food storage industries.

Q: How does kitting improve customer satisfaction?

A: Kitting reduces order fulfillment times, minimizes errors, and ensures accurate packaging, resulting in improved customer satisfaction.

Q: Can kitting be used in e-commerce fulfillment?

A: Yes, kitting is commonly used in e-commerce fulfillment to consolidate frequently ordered items and accelerate the order fulfillment process.

Q: What software can assist with kitting in a warehouse?

A: Warehouse management software (WMS) and barcode scanning systems are commonly used to streamline and optimize kitting operations.

Q: How can kitting contribute to cost savings in a warehouse?

A: Kitting can help minimize order picking time, reduce errors, and improve overall operational efficiency, leading to cost savings in labor, inventory management, and customer satisfaction.