The problem isn't always the "big" parts. The issue typically lies in finding the small parts once you've unpacked everything. A common situation occurs when a customer receives a brand-new shelving unit (wood, brackets, tools) only to find out there's one little screw missing. At this point, the entire project grinds to a halt. This issue doesn't have to occur if all of the smaller parts are organized before being shipped.
By organizing your parts into groups depending upon how you plan to use them, you'll have an advantage when assembling your product. It would be silly to take every bolt and nut off the table at the same time. By separating the parts and placing them into separate bags, you can create a process that makes sense. For instance, the screws for the first step in a process would remain in the same bag. Similarly, the bolts for the final steps could remain in their own individual bag.
Organizing and counting your parts prior to packaging can eliminate problems after receiving your parts. In addition, labeling your bags can allow both you and the customer to quickly identify exactly what's inside. A few examples of labels that you could use include "First Step," "Wall Mount," and "Four Short Bolts." Labels provide clarity so you can quickly locate the correct part. Additionally, clear poly bags will enable both you and your customer to see what's inside while making it easy to view the label on each bag. This can assist in expediting assembly and decrease the potential risk of utilizing incorrect components.
While organizing your parts, you must remember to consider any sharp edges. Sharp objects like nails, metal clips, etc., can puncture thinner poly bags if they're impacted in some manner. Thicker bags can protect these types of parts. Wrapping sharp ends of components with tape or adding an inner protective layer (e.g., foam or bubble wrap) provides additional safety.
In addition to protecting your parts from damage while they are stored, sealed bags also provide protection from debris and dust accumulation while waiting to be packaged. While storing parts in open bins, employees may accidentally pick up the incorrect size or quantity due to poor visibility. Using sealed bags will promote organization of corresponding pieces and also prevent the contamination of clean parts by dust particles while supplies await shipment.
For certain products, specific requirements may exist for storage and bagging. For example, computer parts may require anti-static bags to minimize static buildup. Components that contain metal that can rust may require additional moisture-proofing measures. Do not treat standard plastic bags as a solution if special considerations apply to your product.
A well-organized packing station will facilitate the overall process. Keep bags, labels, part lists, and completed kits readily available. Make sure your workers have sufficient space to count each group of pieces without confusion between multiple orders. Check one complete kit before packing the remaining kits to ensure no errors were made.
Small components may appear insignificant; however, many times they determine whether a product functions properly. Organize, count, and clearly label each component group using poly bags, and you can convert a disarray of loose components into a kit that customers feel confident about opening.
