Kitting & Assembly
Kitting is the process of grouping individual items into a single, ready-to-ship or retail-ready package. Productiv assembles 30 million+ kits annually — subscription boxes, retail gift sets, industrial kits, promotional packages, display builds, and repack programs — across facilities in Dallas, Charlotte, and embedded sites nationwide.
Every program is priced per unit, not per hour. Every kit is built by a W2 workforce with no temp agencies. And every program benefits from 20 years of solved kitting problems — including operator-built quality tools and cobots running in live production.
Based on live program data from Productiv operations — last updated March 2026
Kits annually
Single programs up to 80,000 kits per day.
Accuracy target
100% for regulated and compliance programs.
No temp agencies
Line leads average 10+ years tenure.
Program launch
For rework and manufacturing-return programs.
13 cobots + 2 humanoids in live production
Every kitting program type, under one roof
From 200-unit influencer mailers to 20-million-unit annual loyalty programs — we've run them all. The complexity changes. The discipline doesn't.
Subscription Box Kitting
Monthly and seasonal programs with variable SKU configurations, multi-item bundles, and coordinated ship dates. Single programs run 150,000–200,000 kits per month.
Retail Gift Set Assembly
Seasonal gifting programs for major retailers — beauty sets, holiday kits, promotional bundles. One program runs 3–4 million kits per year with monthly configuration changes.
Industrial & Manufacturing Kitting
Parts staging, component kitting for assembly lines, and lot/batch controlled programs. Clean room capability for regulated products including medical devices.
Contract Packaging
Primary and secondary packaging, shrink wrap, retail-ready packaging, co-packing, and display packaging. Often combined with kitting in a single program.
POP Display Assembly
Point-of-purchase floor displays, PDQ trays, planogram-compliant builds, and retail shelf-ready packaging. One client reduced materials by 25% and excess by 90% within 2 weeks.
Repack & Relabel
Repackaging, compliance relabeling, rework, and product recovery. Productiv has repacked 500 pallets in 22 days and processed 175,000 pieces in 14 days for clients.
Amazon FBA Prep
FNSKU labeling, poly bagging, bundling, and shipment creation to Amazon fulfillment centers. Compliant with Amazon packaging and prep requirements.
Promotional & Marketing Kits
Influencer mailers, event kits, product launch packages, and sample sets. Variable configurations, personalization, and custom packaging supported.
20 years of solved kitting problems
Most kitting problems aren't new. Vendor concealed shortages, First Article mismatches, lot control gaps, count discrepancies on program transfers — we've seen all of them, solved all of them, and built tools to prevent them from recurring.
When you start a program with Productiv, you're not paying for us to learn your industry. You're inheriting 20 years of solved problems.
"We are hitting all the SLAs over and over again. Productiv has led the charge and brought so many improvements to the table over the last two years. There's nothing glaring that stands out anymore and now we are just fine tuning."
Kelli Overson, EVP of Operations — Pourri
W2-only workforce. No temp agencies.
Every operator on your program is a Productiv W2 employee. Line leads, supervisors, and account coordinators average 10+ years of tenure. The institutional knowledge stays on your program — not cycling through every 90 days.
ProQuality — First Article before every run.
Our operator-built AI quality tool auto-routes First Article photos to your team for approval before the full run begins. The most common source of kitting errors — incorrect configuration approved verbally but not validated — is eliminated at the start.
Per-unit pricing. No hourly billing.
You pay per kit, not per hour. That means our incentive is to build kits faster and more accurately — not to bill more time. Efficiency gains flow to you as lower cost per unit, not to us as margin padding.
Cobots and humanoids in live production.
13 cobots and 2 humanoid robots run alongside human operators on kitting lines at our Dallas facility. Robot pick accuracy has reached 99%+ on validated SKUs. Every program benefits from the ongoing improvement as robot capabilities expand.
Programs we've run
Real programs. Real numbers. Anonymized where required.
Major beauty brand — loyalty program
20 million kits per year. 5 SKU varieties. 1,000+ units per hour across multiple lines. Monthly configuration changes managed without line stoppages.
Major beauty brand — seasonal gifting
3–4 million kits per year. 15–18 items per kit. 100,000+ kits per day at peak. 3-second takt time per item. Retail launch dates held without exception.
Subscription fishing and tackle program
150,000–200,000 kits per month. 30–50 SKUs per kit. 7–10 items per kit. Running at 720 units per minute with cobot and humanoid robot augmentation.
Outdoor safety brand — first aid kits
Up to 100 items per kit. Lot and batch control across 75 regulated items. Regulatory documentation per job. 100% accuracy requirement maintained.
FEMA disaster relief — meal program
2.7 million meals packed in 2 weeks. Procurement and sourcing included. Zero lead time — program stood up within 48 hours of contract.
Medical device manufacturer — surgical trays
Clean room kitting with full lot traceability. Expanded scope from kitting into upstream picking after identifying missing components as root cause of line stoppages. Throughput improved significantly.
Per-unit pricing. Transparent from day one.
Productiv prices kitting on a per-unit basis. No hourly billing, no hidden fees, no line-item engineering charges. The pricing model aligns our incentives with yours: we earn more by working more efficiently, not by billing more hours.
// RATE_STRUCTURE
Base fee driven by lot/batch control, special labeling, packaging type, and required accuracy tolerance. Get an exact quote for your program.
What affects your per-unit rate
Kitting questions, answered
Everything buyers ask us before starting a kitting program.
Tell us about your kitting program.
Whether you're launching a new program or moving an existing one, we'll tell you honestly what we can do and what it would cost. No pitch decks. No pressure.