One Tray, One Build, One Set of Papers
Designing the tray around the assembly, not the part
A single-part tray optimises for one cavity shape repeated. A kitting tray optimises for a sequence: the operator should be able to work left to right, taking each part in build order without hunting. Cavity numbering, a printed legend on the tray floor, and one cavity per part number are the three things that make this work.
The temptation is to pack tightly. Resist it. Each cavity needs enough clearance that a part drops in without being forced, because a forced fit is how a kit arrives one piece short. Where quantities per build are small, add a spare cavity rather than a loose bag — loose bags inside an ESD tray defeat the point of the tray.
Papers travel with the kit
A kit is only useful if the contents can be verified without opening every compartment twice. Put the part numbers, quantities and revision on a traveler that sits in a dedicated document pocket, or print them on the lid. A revision mix inside one kit is the most expensive error in this workflow, because it is discovered at final test rather than at goods-in.
Counting is the recurring failure. Build the count into the tray geometry where possible — one cavity per piece means a missing part is visible at a glance — and define what happens when the count is wrong. A short kit that gets waved through once will be waved through every time after that.
FAQ
What is an ESD kitting tray?
A tray that holds every part for one assembly in build order, so the line picks one tray per unit instead of pulling individual part numbers from stock.
How should cavities be arranged for a kit?
In build sequence, numbered, with a printed legend on the tray floor and one cavity per part number, sized for a drop-in fit rather than a press fit.
How do you prevent revision mix in a kit?
Put part numbers, quantities and revision on a traveler in a document pocket or on the lid, and verify at kitting rather than at final test.
How do you catch a short kit?
Use one cavity per piece so an empty pocket is visible, and define a rework step for incorrect counts instead of accepting them.
All figures above refer to standard product data sheets; final confirmation is subject to written quotation.