This charter outlines a project to increase the level of kitting on the production line. Currently, materials are held trackside rather than being kitted. The project will analyze increasing kitting over time. The engineering and manufacturing BOMs need to be accurately aligned to drive routings that define where kits are required. Benefits include more effective space use, reduced line feeding, and better stock control. The scope includes most material except high volume, low cost parts. Deliverables are to analyze work content, route BOMs to stations, assess SAP changes, identify best kitting process, test and refine the solution, and provide training. Risks include resource constraints from other projects and BOM/routing changes. The

1. Shneha Rajesh Patel Charter 24/11/2015
CHARTER TO DEVELOP A SOLUTION FOR A KITTING PROCESS
Change management
Version Nature of change Changed by Date
BUSINESS CASE
Currently the kitting levels on the production line are low. All the materials are
being held track side. Materials that are being kitted are either DTO (design to
order) or selected low usage parts. This project will examine the potential to
increase this significantly over a period of time. The engineering and
manufacturing departments have separate BOM (Bill of materials). The
engineering BOM deals in placing part numbers in correct groups. The
manufacturing department then puts these groups into routings to correspond with
the correct operation or workstation and this is what controls the kitting process.
The BOM (Bill of material) needs to be accurate as this drives the routings that
will define where the kits are required on the build line.
BENEFITS
• More effective use of space at trackside. Reduced line feed operations.
• Better control of stock
• Reduce the multiple locations for the same material at trackside
SCOPE
In Scope
• All material except for high volume low value parts will be considered.
• All standard price list options
• Build line and sub-assembly
• Pre and Post-test build
• DTO (design to order)
• Assess the accuracy of the BOM and routings of the material.
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2. Shneha Rajesh Patel Charter 24/11/2015
Out of scope
• Hardware - high volume low cost items
• Serialised material
DELIVERABLES/ KEY REQUIREMENTS
• Analyse the data to assess the work content in stores. Time studies may be
required for the work content of the kitting process.
• Routing the BOM to the correct station or operation.
• Assess the possible changes to SAP viewer.
• How to identify the part numbers in the kit.
• Identify the best kitting process for a good outcome.
• Propose the most efficient and effective solution.
 Kit for week – station-day-operation-engine
• Test the proposed solution and see what the outcomes are. Based on these
outcomes, refine or carry on with the process.
• Documentation and training for employees in the stores and the build line.
• Phase implementation – Testing the kitting process in small phases
depending on whether it is to be kitted to an engine, per week, operation
stations or per day.
ASSUMPTIONS, CONCERNS, RISKS, CONSTRAINTS
1. Assumptions
• Adequate space for kitting in stores and on the build line.
• Routings would have to be up to date and accurate for the kitting to be
delivered to the correct stations or operation when needed.
• BOM have to be up to date.
2. Concerns
• The team changing CAT part numbers to dashes after 3 digits on the SAP
viewer programme due to an update.
• The project needs to understand the implications when it comes to the
routings.
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3. Shneha Rajesh Patel Charter 24/11/2015
• Is the kitting process going to be taken on-board before or after the build
line is moved into the new facility?
• The kitting will be based on the published production schedule which
will limit the opportunity to change.
• The effective dates on engineering changes will affect the kitting and
limit the ability to change the build schedules.
3. Risks
• Other projects are running simultaneously with this project and are using
the same resources. There would be the issue of prioritisation.
• Changes of part numbers to include hyphens.
4. Constraints
• Other projects are running simultaneously with this project and are using
the same resources. There would be the issue of prioritisation.
ADVANTAGES OF KITTING
• Higher stock accuracy, (97% and above current figure)
• The operator does not have to go looking for the material hence increasing
the productivity. E.g.
o C9 engine was picked as a kit before where the parts were placed on a
kit trolley and wheeled to the operating station.
• Material delivered based on production schedule. This increases the
efficiency of the system.
• Kit per engine means there is no space and time delay.
DISADVANTAGES OF KITTING
• Limitations for the production manager to change his mind at particular time
in the day.
• Possibility could increase kit pickers – Could increase more personnel to
increase the kits. Over staffed. Reduce line feeding.
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4. Shneha Rajesh Patel Charter 24/11/2015
• Time – is there enough time to do the kits? How long will it take to pick
each kit and deliver it to the appropriate operating station? The stability of
the schedule must be related to the amount of time taken to prepare the kit.
• Space-trolley-quantity of kit
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