Test component kitting with missing, extra and wrong items, interrupted kits, refills and recipe changes. Record accepted kit output and controlled recovery.
Photographs illustrate component feeding and transfer. Component identity, quantities and complete-kit release must be proved with representative parts and the intended receiving pack.
Agree the complete-kit recipe and expected result for each challenge before testing. Use representative parts and the intended receiving pack to test missing, extra and similar-looking wrong items. Include stopped cycles, empty supplies, refills, container changes and recipe changes; retain incomplete or uncertain kits for controlled recovery.
Follow the component kitting sequence and define the check capabilities and selection limits. A cycle count or aggregate measurement alone does not prove that every required component reached the correct kit.
Plan automated component kit preparation around real component variation, bulk condition, orientation, usable delivery rate and the downstream interface. Discuss representative part trials with Sorting Solutions. Use this guide to resolve jam, damage and recovery acceptance checks before it limits the final system.
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Record the kit recipe and revision, component references and quantities, receiving container or positions, expected result and observed checks. Include the supply state and any components already present when a cycle is interrupted.
Use normal, marginal and supplier-variant components in realistic bulk or tray conditions. Challenge missing, extra and similar-looking wrong items, an empty supply and refill, a partly built kit, container removal or replacement and a change between similar recipes.
Record accepted, incomplete, reworked and uncertain kits separately. Check the downstream handover, the agreed hold or rework response and the recheck after recovery. Include refill, checking, recipe-change and recovery time when assessing complete-kit output.
Approve the bill of materials and recipe revision, with component identifiers, quantities, permitted substitutions and receiving positions. Identify plausible missing, extra and wrong-item cases with an expected result for each.
Trial actual part surfaces and fragile or entangling components. Retain observations of separation, orientation and damage, and record where an alternative presentation method is needed.
Run representative supply levels, an empty feeder and replenishment. Account for components remaining in supplies and part-complete containers before a recipe change; record how uncertain supply or kit states are contained.
Measure accepted complete kits for the agreed product mix. Include refills, checking, recipe changes, rework and rejected kits, keeping individual feeder speed distinct from usable complete-kit delivery.
Confirm the intended receiving pack and positions. Challenge container removal, replacement and an interrupted cycle; verify that the completion result stays associated with the correct kit and downstream handover.
Interrupt dispensing after some components are present, then demonstrate the agreed reconciliation and recovery without a duplicate fill. Test controlled rework and recheck; retain missing, extra, wrong-item and uncertain outcomes rather than treating them as accepted kits.