Kitting CKD pour une usine d'assemblage : Égypte
Client
A motorcycle assembly plant in Egypt
Secteur
CKD Assembly
Indicateurs clés
Le Défi
The plant assembles two motorcycle models from imported kits. Parts arrived in bulk cartons sorted by part number, which meant that before each production run the warehouse spent close to two days sorting 60 part numbers into model-specific sets.
Any shortage discovered during sorting stopped the line. Because the shortage was only found at that point, there was no time to air-freight a replacement, and the plant either built incomplete units or idled.
Corrosion was a secondary issue: parts sat in humid storage for weeks between unpacking and assembly.
Notre Solution
We moved the sorting upstream, into our own packing line.
- Kit per model: every carton one model, every part inside counted to the bill of materials for one unit, with a 2% consumable allowance on fasteners.
- Labelling: barcode labels generated in the plant's own ERP format, so receiving scans straight into their system with no re-keying.
- Protection: VCI bags for steel parts and a desiccant per carton, which solved the corrosion without oiling.
- Replenishment: a two-week kanban buffer held on our side, triggered by the plant's consumption signal rather than by their purchase order cycle.
- Audit: each kit weighed before sealing, with the weight recorded on the label — a fast way to catch a missing part before it reaches Egypt.
Le Résultat
Line-side stock dropped about 45% because the sorting buffer was no longer needed, and kit fill rate settled at 96% over the following year. Line stoppages attributable to parts shortages fell to occasional single-shift events instead of a recurring weekly problem.
Corrosion rejections at receiving effectively stopped after the VCI change.
The hidden cost of bulk cartons
Buying by part number is cheaper per unit and more expensive per vehicle. The difference shows up as warehouse labour, as floor space tied up in a sorting buffer, and as line stoppages that nobody attributes to the packing method because the immediate cause is always "a missing part".
Kitting moves that labour to the supplier, where it is done once at a lower cost, and it converts a shortage discovered at the worst possible moment into a shortage discovered before the carton was sealed.
Why the weight check works
Counting 60 part numbers per kit by hand is not reliable at volume. Weighing the sealed kit against a calculated target is fast, objective, and catches the one thing that matters — a missing item — without inspecting every bag. It does not catch a wrong part of similar weight, which is why the packing line still runs a first-article check at the start of each batch.
What a plant should specify
Specify the kit definition in the plant's own BOM structure, not the supplier's catalogue structure. Specify the label format the receiving system can scan. And specify what happens when a kit is short — a rework clause is cheaper to agree before the first shipment than after the first stoppage.
Points forts du projet
- Méthodologie de développement agile
- Chef de projet dédié
- Support et maintenance 24/7
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