Kitting & Sequencing

    Kitting and Sequencing — Build It Right the First Time

    Kitting and sequencing operations require exact component selection in exact order. A single missed part or wrong sequence can scrap an entire assembly. Voodoo's wireless light-directed displays guide operators step-by-step through multi-component builds, lighting up the correct part bin in order and confirming each pick before advancing. Whether you call it kitting, assembly sequencing, or line-side replenishment, the principle is the same: eliminate human error from complex, repetitive processes.

    How It Works

    Light-Directed Assembly in Four Steps

    Every kitting and assembly workflow follows the same guided sequence — load, pick, confirm, complete. The system enforces the correct order so operators never miss a step.

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    1

    Work Order Loads

    Displays light up the first component bin in the sequence, showing part number and quantity needed.

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    2

    Operator Picks

    The operator picks the lit component — the display shows part number, quantity, and placement instructions.

    ✅
    3

    Confirm & Advance

    A button press confirms the pick. The next bin in the sequence lights up automatically.

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    4

    Kit Complete

    All components confirmed — kit is complete and the system logs the build with full traceability.

    Measurable Impact on Assembly Quality

    Light-directed kitting transforms error-prone manual processes into guided, verifiable workflows. Results are immediate and measurable.

    99%+
    Reduction in Assembly Errors
    Hours
    To Train New Operators
    Real-Time
    Build Tracking & Metrics
    Zero
    Wiring Required
    Calculate Your ROI

    When to Use Kitting & Sequencing

    • ●Multi-component assembly where sequence and part selection matter
    • ●Production line kitting — delivering exactly the right parts to each station
    • ●MRO and maintenance kits with mixed part types and regulated traceability
    • ●Subscription box assembly with varying product mixes per tier
    • ●Any pick-to-kit workflow where missing a single component scraps the build

    Why Wireless Guided Kitting

    • ●Reconfigure kitting stations and bin layouts in minutes — no rewiring
    • ●Add part bins for new product lines without infrastructure changes
    • ●Battery-powered displays last years — no power runs to each bin
    • ●Deploy a light-directed assembly station in hours, not weeks
    • ●Same Voodoo hardware used for pick-to-light also runs guided kitting

    What It Integrates With

    • ●Any WMS or MES via standard REST API for work order data
    • ●ERP systems (SAP, Oracle) for BOM-driven kitting instructions
    • ●Barcode scanners for component-level verification at each step
    • ●Downstream pack-to-light for ship verification after kit assembly
    • ●Cloud dashboard for build completion, cycle time, and error tracking
    How It Compares

    Kitting & Sequencing vs. Other Workflows

    Light-directed assembly — also called guided kitting, pick-to-kit, or sequenced picking — enforces build order on every pick. Here's how it differs from other approaches.

    Kitting vs. Pick to Light

    Standard pick-to-light (pick-by-light) lights up locations for discrete order picking — any sequence works. Kitting and sequencing enforces a strict build order: each bin lights only after the previous step is confirmed. Both run on the same hardware, but kitting adds sequence enforcement for assembly-critical workflows.

    Kitting vs. Batch Picking

    Batch picking consolidates multiple orders into one retrieval trip — fast but unguided. Kitting (light-directed assembly) builds one complete kit at a time with verified component selection. Batch picking optimizes for speed across orders; kitting optimizes for accuracy within a single multi-component build.

    Kitting vs. Pack to Light

    Kitting guides the assembly of components into a complete kit — building the order. Pack-to-light (pack verification, ship verification) confirms the assembled order is correct at the pack station. They are sequential: kitting builds it, pack-to-light verifies it. For operations that need both, the same Voodoo displays handle both steps.

    Use Cases

    Where Light-Directed Kitting Delivers

    From manufacturing floors to distribution centers, kitting and sequencing with visual guidance applies wherever operators assemble multi-component orders.

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    Manufacturing Kitting

    Assemble component kits for production lines with exact part counts and sequence enforcement. Reduce line stoppages caused by missing or incorrect parts.

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    Automotive Parts Sequencing

    Deliver parts to assembly stations in exact build order. Light-directed sequencing ensures the right component arrives at the right time for each vehicle.

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    Electronics Assembly

    Guide operators through complex PCB and device assembly sequences where component orientation and placement order are critical.

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    Medical Device Kitting

    Meet regulatory compliance requirements with fully traceable, light-directed kitting that logs every pick for audit trails and quality documentation.

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    Line-Side Replenishment

    Displays at production line stations guide replenishment picks, ensuring the right materials reach the right workstation before stock runs out.

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    Will-Call Staging

    Pre-build customer orders into staged kits for quick pickup. Each kit is verified complete before reaching the staging area.

    Explore all use cases
    FAQ

    Frequently Asked Questions

    What is kitting?

    Kitting is the process of assembling individual items into a kit or set for a specific purpose — whether that's a production work order, a customer shipment, or a maintenance repair package. Instead of picking items one at a time across separate orders, kitting groups all required components together so downstream processes receive a complete, ready-to-use package.

    What's the difference between kitting and sequencing?

    Kitting focuses on gathering the correct parts into a set. Sequencing adds an order-dependent dimension — components must be picked or delivered in a specific sequence to match assembly steps. Voodoo's light-directed system handles both: it can guide operators through unordered part collection or enforce a strict pick sequence where each step must be confirmed before the next bin lights up.

    How does light-directed kitting reduce errors?

    The operator follows the lights — only the correct bin illuminates at each step, and a button press confirms the pick before the system advances. There's no opportunity to skip steps, pick from the wrong location, or grab the wrong quantity. The display shows exactly what to pick, how many, and where it goes. This approach, built on the same pick-to-light technology used across warehouses, achieves 99%+ accuracy in kitting and assembly operations.

    Can this work for line-side replenishment?

    Yes. Displays mounted at production line stations guide replenishment picks by lighting up the exact bin that needs restocking. The system can trigger replenishment signals based on consumption rates or manual requests, ensuring materials arrive at the workstation before stock runs out. Because the devices are wireless, they can be repositioned as line layouts change.

    What industries use light-directed kitting?

    Light-directed kitting is used across manufacturing, automotive, electronics, and medical device industries — anywhere multi-component assembly demands accuracy and traceability. Medical device manufacturers value the audit trail for regulatory compliance. Automotive plants rely on sequencing for just-in-time delivery to assembly stations.

    How does kitting integrate with our ERP or MES?

    Voodoo's system connects to your ERP, MES, or WMS through a simple REST API. Work orders flow in, and pick confirmations flow back in real time. The same integration approach used for WMS pick-to-light applies to kitting and sequencing workflows — no middleware required.

    Related Workflows & Resources

    Pick to LightPack to LightPut to LightPut WallsUse CasesIndustriesWMS IntegrationROI CalculatorNehemiah Case StudyPick by Light vs Pick to LightWireless Pick-to-LightOrder Picking CartsPick to Cart

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