Kitting process in a stochastic assembly system

In small-lot, multi-product, multi-level assembly systems, kitting (or accumulating) components required for assembly plays a crucial role in determining system performance, especially when the system operates in a stochastic environment. This paper analyzes the kitting process of a stochastic assembly system, treating it as an assembly-like queue. If components arrive according to Poisson processes, we show that the output stream departing the kitting operation is a Markov renewal process. The distribution of time between kit completions is also derived. Under the special condition of identical component arrival streams having the same Poisson parameter, we show that the output stream of kits approximates a Poisson process with parameter equal to that of the input stream. This approximately decouples assembly from kitting, allowing the assembly operation to be analyzed separately. We also show that, in the long run, all inventory positions are equally likely and independent of the actual inventory position.