Picklist Processing - Kit Items

A Kit item is an item that is actually composed of multiple component parts.  The kit item itself does not actually exist, and it is used to allow the operator to enter one item number (one sales order line) for a group of parts that would normally be ordered as multiple sales order lines.  Kit items are defined in a Bill of Materials record, and this bill of materials record contains the component items and quantities that are shipped to the customer when the kit is ordered.

Kit or kitted items are also sometime referred to as bundles or bundled items

Examples of kit items might include a computer/monitor/keyboard combination, or a tv mount with cables, and installation supplies, or an upholstery kit for an automobile (seat covers, carpet, door panels).

Since the kit item does not actually exist, and since it is defined by information that is only in your system, a kit item cannot be flagged as serialized.  Kit components can be serialized items, and if serialized items are included in a kit, the system updates (or creates)  the serial records for the component items during the invoicing  process.  A kit item must be set up as a tracking item, and a kit item may not be special ordered or vendor shipped (it must be processed as a warehouse shipment).

One other important behavior unique to kit items is that the system will only allocate to a kit sales order line when all of the components required for the line are available.  This allows the kit components to be sold individually when there are not enough components to complete the order line for the kit part (if a kit order for qty 5 is entered and the lowest component qty available is 4, the system will only allocate the 4  - so the other components can be sold individually).  The number of components allocated for each kit is shown in the sales order line for the item, and this quantity and the bill of materials for the kit items are used by the system to print the component quantities that actually need to be picked for the order.

If a kit item is being processed during order fulfillment, it has already been allocated to by the system (this process is described in detail in the documentation for the Order Processing System).

The following steps are used to complete an order line for a kitted item.

•      Print the picklist for the sales order.  The picklist will list any kit components and any non kitted parts to be shipped out against the sales order.  The picklist will also print a section at the end of the document that indicates that “This pick list Contains one or more Kits consisting of the following parts” and then it will list the components contained within the kit.  This section will print once for each of the kit items being processed for the order on this picklist.

•      Physically pull the items to be shipped out against the sales order – based on the pick detail. 

•      Once the component items have been picked from the shelves, you should use the StreamII System or an RF Gun to execute the RFPICK program.  This program is used to input the serial numbers for any serialized kit components, and this step MUST be completed before you can process any order containing a kit part with serialized components.  Once you execute the program, it will prompt the operator to scan each of the the items for the sales order.  If any of the items are serialized, the system will also prompt for the serial numbers for the serialized item.  Once you have finished entering the item numbers and serial numbers for the shipment, the program will display a Done message, and return to the menu.

•      Load the pick into the Order Invoicing /Completion program.  Note:  The line item detail displayed in the Order Invoicing program – Order Lines Tab will differ from the picklist detail when a kitted item is being processed.  The picklist will list the actual component items being shipped for each kit, while the Order Invoicing program will display the kit items themselves.

•      Complete the order.  You should not need to modify the quantity of any of the kitted items showing in the order lines section.  If you were unable to pick the required components shown on the picklist for a kit item, you should reset the pick and correct the component quantity in the system before invoicing the order.  The process of manifesting and shipping a kit order is the same as for other stocking items.

•      As the order is completed, the system will create an invoice for it, and it will update (or create as necessary), the serialized inventory detail for the serialized component items.  This serial detail can be viewed from the invoice lines for the kit items using the view serial numbers option.

•      Again, please note, when a kitted item is processed, the order and invoice for the kit item will show the kit part.  The picklist itself will show the component items for the kit.  The serial detail for the kitted components must be input using the RFPICK program and this serial detail is then updated and linked to the invoice line for the appropriate kit item.


Picklist Processing - Order Completion