RELY · Case Study · Industrial distributionNO. 11
WHEN A KIT PROGRAM BECOMES A COORDINATION PROBLEM
300,000 kits. One coordinated program.
A national industrial distributor needed 300,000 hardware installation kits for a manufacturer customer. Packaging supply, prebuilt subcomponents, build capacity, quality checks and release dates all had to line up.
RELY coordinated them as one program instead of leaving the customer to stitch them together.
View the original PDF- 300,000Kits. Program completed in full
- 18 daysFrom kit assembly start to the first 40,040-kit shipmentMarch 2 to March 20, 2026
- 83,000+Tape subcomponents prebuiltWhile production packaging was still inbound
- 410Kit pilot shippedDecember 8, 2025
This took more than adding people.
Packaging supply, advance preparation, assembly, quality checks and releases had to work together.
Kit assembly could not start until the customer-supplied custom bags and the RELY-sourced cartons, labels and pallets were in hand. RELY used that window to build ahead.
HOW THE WORK FIT TOGETHER
- 01
Coordinate the packaging
Sourced cartons, carton labels and pallets, and planned the build around the customer-supplied custom bags.
- 02
Build ahead of the constraint
Shipped a 410-kit pilot, then prebuilt 83,000+ tape subcomponents while production packaging was still inbound.
- 03
Scale the build
Expanded the trained build team and added a second shift.
- 04
Stage and release
Staged finished kits and shipped full 40,040-kit lots on the release schedule, then the final balance in August.
PROGRAM MILESTONES · PO RECEIVED OCT 29, 2025
- DEC 2025
Pilot
410-kit pilot shipped Dec 8.
- JAN 12, 2026
Advance prep
Subcomponent prebuild began.
- MAR 2 TO MAR 20
First full lot: 18 days
Kit assembly began Mar 2. First 40,040-kit lot shipped Mar 20.
- AUG 2026
Completion
Final balance shipped. 300,000 kits complete.
Releases followed the customer's schedule. October to August is the program's overall duration, not a production lead time.
HOW IT WAS CONTROLLED
RELY documented the build in a 20-step work instruction with kit-weight and bag-seal checks. Production and shipment quantities were recorded in RELY's ERP.
The value was not simply more assembly capacity. RELY coordinated the packaging, preparation, build and release work within one program.
SOURCE: RELY INTERNAL PROGRAM RECORDS. CUSTOMER NOT NAMED. RESULTS REFLECT THIS PROGRAM ONLY AND ARE NOT A STANDARD LEAD-TIME OR CAPACITY COMMITMENT.
START HERE
Is your next kit program becoming another operation to manage?
Tell us where the work is getting stuck. You can start with one kit family. When you're ready to scope, bring the BOM, quantity, packaging requirements and release schedule. Confidential files? Ask about our NDA process.
Related services
Related industries
All case studies and field notes
The original PDF is available to download.