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Inventory Management

Nov 14, 2023

Improve Warehouse Operations with Warehouse Kitting

Discover the power of warehouse kitting and how it can revolutionize your operations. Streamline order fulfillment, reduce costs, and more.

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Kits, bundles, oh my! 

Warehouse kitting has emerged as a highly sought-after practice due to its multitude of advantages it offers to businesses. By implementing effective warehouse kitting strategies, businesses can streamline their order fulfillment process, significantly reduce shipping costs, and create an unforgettable customer experience. 

In this comprehensive guide, we will learn about the intriguing world of warehouse kitting, how it differs from assemblies, its benefits, and how it has the power to revolutionize your warehouse operations for the better.


Topics we will be covering:

Understanding warehouse kitting

Warehouse kitting is a highly effective inventory management technique that involves bundling individual items or product SKUs to create a single kit ready for shipment to a customer. Businesses utilize kitting to mix and match different products to increase profits and reduce expenses by consolidating products into as few packages as possible. This streamlined approach to order fulfillment reduces pick and pack time and shipping costs. It can also be particularly beneficial to e-commerce businesses, where it is used to create subscription boxes, gift sets, and bundled products.


The difference between kits, bundles, and assemblies

Understanding the distinctions between kits, bundles, and assemblies can be a bit of a head scratcher. Let’s take a look at these terms and unravel their similarities and differences. 

To start, let's take a look at kitting and bundles. Both refer to the process of bundling items together. Essentially, kitting and bundles are interchangeable. A bundle is essentially a kit, and vice versa. However, businesses may have their own preferences for how they prefer to refer to them. 

On the other hand, assemblies stand apart from kitting and bundling as they are prepackaged or assembled specifically for stock purposes. 

A way that you can tell these terms apart is: 

  • Kitting/bundles - are built to order
  • Assemblies - are built (or assembled) for stock

The kitting process

When it comes to the kitting process, there are four key steps that are included:

  • Select items for kitting: Determine which products will be included in a single kit based on strategic grouping, category, or season. 

  • Create a SKU: Assign a new SKU to the kit in your warehouse management system (WMS) to track and analyze its performance. 

  • Assemble the kit: Assemble the selected items into a single package in an assembly area of your warehouse.

  • Packaging customization: Customize the packaging to enhance the customer unboxing experience and reinforce your brand identity. 

benefits of kits for your warehouse

Benefits of warehouse kitting

By implementing warehouse kitting strategies in your order fulfillment process, you can unlock a wealth of advantages, including cost savings, enhanced customer satisfaction, and optimized inventory management. While there are numerous benefits to be gained from warehouse kitting, let's focus on the top four that can truly transform your operations.

Save money

Effective kitting strategies can streamline inventory management, cut down on packaging expenses, and minimize shipping costs by consolidating multiple products into fewer packages. Instead of sending out separate small packages, you can now send out a single package containing all five items. This not only saves you money but also improves the efficiency of your order fulfillment process. 

Get rid of expiring perishable products

Bundling products that are nearing their expiration date with other items can increase the products' appeal and create an opportunity for customers to try new items. This win-win situation allows you to sell soon-to-be-expired stock before it goes bad while providing customers with value packs or gift sets. It's a great way to avoid waste and offer an exciting experience to your customers. 

Improve the customer experience

The delight of receiving a complete kit instead of a slew of smaller packages can create a more memorable unboxing experience for customers. It’s like treating yourself to a little gift. Even if you already know what’s inside, there’s still a sense of excitement as you open the package and explore all the items within. 

Inventory optimization

Kitting makes it possible for you to manage inventory more effectively by grouping related products together, improving order tracking, and reducing the risk of stockouts and overstocking. 

Leveraging kitting benefits to the fullest with Zenventory

To unlock the full potential of warehouse kitting benefits, you will need the right inventory management software. Zenventory is a cutting-edge cloud-based solution that provides a wide range of features to optimize your warehouse operations. 

Experience the power of Zenventory and gain the ability to ...

Efficiently manage inventory

Easily import item details, set up multiple units of measure, and create variants. Zenventory also supports lot numbers, serial numbers, and expiration dates to effectively track inventory. 

See the future with forecasting capabilities

Predict the future with the same report you use to see how products are selling lately. Gain valuable insights like: How many days of inventory do you have left for each product in stock based on current sales velocity.

Conduct cycle counting

Conduct routine cycle counts to uphold precise inventory levels, eliminating the need for laborious full-scale inventory checks.

Automate replenishment

Keep your products that are selling fast stocked up and leave dusty, slow-moving items off your re-order list - automatically without having to manually do anything at all. 

Manage multiple warehouses

Have multiple warehouses? No problem! Zenventory makes it easy for you to manage inventory across all of them in one system. You can even designate different shipping strategies for each warehouse and easily transfer inventory between locations.

Receive and put away goods

Utilize Zenventory’s innovative computer, tablet, or mobile application to streamline the receiving process and effectively organize goods in the optimal warehouse locations. 

Send low stock alerts

Zenventory sends customizable email notifications when stock levels reach minimum thresholds, expiration dates are approaching, or inventory is depleted. You can also set up SMS text message alerts to key personnel. 


Warehouse kitting and best practices

To maximize the potential of warehouse kitting, it’s essential to adhere to certain best practices. Here are the top four recommendations for optimizing your warehouse kitting process.


Group products strategically

To maximize your sales potential, it’s important to select products that complement each other or provide a complete solution for your customers. You can group these products based on common themes, seasonal trends, or customer preferences. For example, if you specialize in selling sports equipment, grouping products by sport makes it easier for beginners to buy everything they need to get started. By offering a kit that includes two pickleball paddles, a case, and a handful of pickleball balls, you can increase your sales compared to selling each item separately. 

Kitting strategies to increase profits

Customize packaging to enhance the experience

By offering kits, you gain valuable insights into your customers’ intentions and aspirations. For instance, those who purchase your beginner pickleball kit are likely trying to learn the sport and see what all the buzz is about. You can enhance their experience by customizing your packaging to align with your brand and create an unforgettable unboxing moment. Consider including personalized notes or special touches like a QR code that directs customers to a beginner’s guide video you’ve created. 


Efficient assembly area

Allocate a designated space within your warehouse exclusively for putting together kits. Organize it in a way that optimizes the efficiency of your workflow and minimizes the time needed to complete each kit. 

Accurate inventory tracking

Implement a reliable and efficient inventory management system, like Zenventory, to guarantee precise tracking of kit components and maintain optimal inventory levels. This proactive approach not only protects against stockouts but also enhances overall inventory management, resulting in a seamless and efficient order fulfillment process. 


Choosing the right warehouse kitting software

When selecting warehouse kitting software, consider the following factors:

  • Ease of use: Look for software that is intuitive and user-friendly. It should be easy to navigate and require minimal training for your team. (No one is going to use software that they don’t know how to use. Instead, they will avoid it like the plague.) 

  • Integration capabilities: Software is only as strong as the integrations it supports. Choose software that seamlessly integrates with your existing marketplaces and platforms.

  • Scalability: You want software that will grow with you. Ensure the software can accommodate your growing business needs and handle increased order volumes.

  • Reporting and analytics: Data is key to a company’s success. Look for software with robust reporting and analytics capabilities to help you gain insights into your kitting operations and make data-driven decisions. 

Overcome common kitting challenges

Common challenges in warehouse kitting

While warehouse kitting offers numerous benefits, it is also important to be aware of potential challenges that may arise when bundling products. Let’s take a closer look at the common obstacles that can occur when you implement a warehouse kitting process. 

Inventory management complexity

Managing inventory can become complex if you rely on Excel spreadsheets. When it comes to kitting, accurate tracking is crucial to ensure all components in the kit are available and accounted for. This is especially important because the availability of a kit for purchase is dependent on the item with the lowest stock in inventory. For example, let’s say you have 50 pickleball paddles, 50 pickleball balls, and 4 pickleball cases. Even if you have 100 paddles in stock, you can only create 4 kits because that’s the number of cases available. 

Packaging and labeling considerations

While customized packaging can elevate the customer experience, it can also complicate the kitting process. If there are any additional elements or specialized packaging for specific kits, it is crucial to have a well-organized system in place that can efficiently manage these extra tasks. 

Kit customization and personalization

Assembling kits requires an extra level of attention to detail, especially because kits are built to order. This can potentially extend the assembly time and complicate the overall process. However, to ensure accuracy and make sure nothing is missed, utilizing a kit list can help make sure that no items are omitted from the package before it is shipped out to the customer. 

Final thoughts

Warehouse kitting is a game-changing solution that optimizes warehouse operations, revolutionizes order fulfillment, cuts down on shipping costs, and leaves a lasting impression on customers. By implementing tried-and-true warehouse kitting practices and harnessing the power of cutting-edge inventory management software like Zenventory, businesses can unlock substantial cost savings, boost efficiency, and take customer satisfaction to new heights.

But here's the thing: warehouse kitting is not just about bundling products together. It's about crafting a seamless and delightful customer journey. By employing the right strategies and leveraging the right tools, you can transform your warehouse into a well-oiled machine that consistently delivers exceptional results.


Don't settle for ordinary. Become extraordinary.

Embrace the power of warehouse kitting and elevate your business to extraordinary heights. Fill out the below form to learn more. 

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