Boost Equipment Reliability with Strategic Kitting: A Proven Approach

In manufacturing, continuous uptime and quality are paramount. Kitting—preparing all required parts and tools in advance—offers a straightforward, high‑impact solution that enhances reliability while minimizing downtime and improving workforce satisfaction.

Before implementing kitting, ask these essential questions to ensure the program delivers real value:

• Is the task urgent, or can it be scheduled at a time that reduces production loss?
• Which materials and tools must be included in the kit?
• Will front‑end coordination add value by ensuring the kit is ready and delivered on time?
• Is the job planned with enough detail to procure the correct materials?
• Do we have sufficient lead time to assemble, inspect, and deliver the kit before the job begins?

Common excuses for avoiding kitting—such as perceived complexity or inventory concerns—are overcome with clear communication, robust inventory management, and proactive job planning. A well‑managed parts inventory guarantees that the right items are available when needed, while accurate lead times enable precise scheduling.

Which work orders benefit most from kitting?

• Planned outages, shutdowns, and turnarounds – kits enable crews to perform high‑quality work within the scheduled window.
• Backlog‑relief tasks – kitting reduces unplanned downtime and helps maintain production schedules.
• Preventive maintenance – repetitive replacement of filters, lubricants, seals, and other expendables should be pre‑packed.
• Technical troubleshooting – where the exact parts needed are uncertain, a “best‑guess” kit paired with a detailed bill of materials (BOM) ensures readiness.
• Routine tasks – if the work is simple or uses common shop items, kitting may be optional; however, scheduled preventive jobs still benefit from it.

Accurate BOMs are critical. They allow planners and crews to pre‑emptively secure parts, reduce on‑site inventory errors, and streamline communication during unexpected breakdowns. A well‑organized storeroom should identify each item’s stock number and location, enabling rapid resupply when high‑priority work arises.

Kit delivery timing is also key. For routine, backlog‑relief, and preventive jobs, deliver the kit the day before the scheduled work to the designated drop zone, shop, or equipment location. This allows crews to verify that all materials are present and correct before work starts, preventing costly disruptions.

The maintenance planner’s role is to confirm the required parts, coordinate with operators and seasoned craftsmen, and perform a pre‑delivery review. Once the kit is issued, the assigned crew performs a final verification; any discrepancies can be addressed before the asset is taken out of service, avoiding unnecessary downtime.

Crash carts or rebuild carts exemplify effective kitting: a reusable container stocked with all the components needed to repair, rebuild, or overhaul a specific asset. After the job, the crew inventories the used items, commits them against the work order, and returns the cart for replenishment. Kits can range from a single bolt to an entire rotating assembly.

By integrating kitting into planned and scheduled maintenance, organizations enjoy higher equipment reliability, increased uptime, reduced operator stress, and smoother overall operations. Although establishing a kitting program requires upfront effort, the long‑term benefits far outweigh the initial investment.

About the Author

Al Emeneker, a subject matter expert at Life Cycle Engineering, brings over 30 years of experience in maintenance, repair, and reliability across companies such as Union Camp Paper Company, Fluor, the U.S. Air Force, and South Carolina Electric and Gas. Contact Al at aemeneker@LCE.com.